3hac046983 PM Irb 1200-En Rev J

ROBOTICS
Product manual
IRB 1200
Trace back information:
Workspace R18-2 version a18
Checked in 2018-11-20
Skribenta version 5.3.012
Product manual
IRB 1200-5/0.9
IRB 1200-5/0.9 type A
IRB 1200-5/0.9 type B
IRB 1200-7/0.7
IRB 1200-7/0.7 type A
IRB 1200-7/0.7 type B
IRC5
Document ID: 3HAC046983-001

Revision: J
© Copyright 2014 - 2018 ABB. All rights reserved.

Specifications subject to change without notice.
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden
Table of contents
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 15
How to read the product manual ...................................................................................................... 17
1 Safety 19
1.1 General safety information .................................................................................. 19
1.1.1 Limitation of liability ................................................................................. 19
1.1.2 Protective stop and emergency stop ........................................................... 21
1.2 Safety actions ................................................................................................... 22
1.2.1 Fire extinguishing .................................................................................... 22
1.2.2 Emergency release of the robot axes .......................................................... 23
1.2.3 Make sure that the main power has been switched off .................................... 24
1.3 Safety risks ...................................................................................................... 25
1.3.1 Safety risks during installation and service work on robots .............................. 25
1.3.2 Moving robots are potentially lethal ............................................................ 27
1.3.3 First test run may cause injury or damage .................................................... 28
1.3.4 Work inside the working range of the robot .................................................. 29
1.3.5 Enabling device and hold-to-run functionality ............................................... 30
1.3.6 Risks associated with live electric parts ....................................................... 31
1.3.7 The unit is sensitive to ESD ....................................................................... 33
1.3.8 Hot parts may cause burns ....................................................................... 34
1.3.9 Safety risks related to pneumatic/hydraulic systems ...................................... 35
1.3.10 Brake testing .......................................................................................... 36
1.3.11 Safety risks during handling of batteries ...................................................... 37
1.3.12 Safety risks during work with gearbox lubricants (oil or grease) ....................... 38
1.4 Safety signals and symbols ................................................................................. 40
1.4.1 Safety signals in the manual ...................................................................... 40
1.4.2 Safety symbols on product labels ............................................................... 42
2 Installation and commissioning 49

2.1 Introduction ...................................................................................................... 49
2.2 Unpacking ....................................................................................................... 50
2.2.1 Extra O-rings ......................................................................................... 50
2.2.2 Protection covers .................................................................................... 52
2.2.3 Transportation bracket ............................................................................. 53
2.2.4 Pre-installation procedure ......................................................................... 57
2.2.5 Dimensions ............................................................................................ 62
2.2.6 Working range ........................................................................................ 64
2.2.7 Risk of tipping/stability ............................................................................. 67
2.3 On-site installation ............................................................................................ 69
2.3.1 Lifting robot with roundslings .................................................................... 69
2.3.2 Lifting and turning a suspended mounted robot ............................................ 73
2.3.3 Manually releasing the brakes ................................................................... 74
2.3.4 Orienting and securing the robot ............................................................... 77
2.3.5 Setting the system parameters for a suspended or tilted robot ......................... 81
2.3.6 Loads fitted to the robot, stopping time and braking distances ......................... 86
2.3.7 Fitting of equipment on the robot ............................................................... 87
2.3.7.1 Introduction to fitting of equipment ................................................. 87
2.3.7.2 Holes for fitting extra equipment .................................................... 88
2.4 Installation of options ......................................................................................... 92
2.4.1 Installing the signal lamp ......................................................................... 92
2.5 Restricting the working range .............................................................................. 95
2.5.1 Axes with restricted working range ............................................................. 95
2.5.2 Mechanically restricting the working range ................................................... 96
2.6 Making robot ready for operation .......................................................................... 101
2.6.1 Additional installation procedure, Clean Room .............................................. 101
Product manual - IRB 1200 5

3HAC046983-001 Revision: J
Table of contents
2.7 Electrical connections ........................................................................................ 102

2.7.1 Robot cabling and connection points .......................................................... 102
2.7.2 Customer connections ............................................................................. 106
2.8 Start of robot in cold environments ...................................................................... 109
3 Maintenance 111
3.1 Introduction ...................................................................................................... 111
3.2 Maintenance schedule ....................................................................................... 112
3.2.1 Specification of maintenance intervals ........................................................ 112
3.2.2 Maintenance schedule ............................................................................. 113
3.3 Inspection activities ........................................................................................... 115
3.3.1 Inspecting the robot cabling ..................................................................... 115
3.3.2 Inspecting the information labels ................................................................ 116
3.3.3 Inspecting mechanical stops .................................................................... 121
3.3.4 Inspecting timing belts ............................................................................ 124
3.3.5 Inspecting the signal lamp (option) ............................................................. 127
3.4 Replacement/changing activities .......................................................................... 129
3.4.1 Replacing the battery pack ....................................................................... 129
3.5 Cleaning activities ............................................................................................. 139
3.5.1 Cleaning the IRB 1200 .............................................................................. 139
4 Repair 143
4.1 Introduction ...................................................................................................... 143
4.2 General procedures ........................................................................................... 144
4.2.1 Cut the paint or surface on the robot before replacing parts ............................ 144
4.2.2 Mounting instructions for seals .................................................................. 146
4.2.3 Sealing differences depending on protection class ........................................ 148
4.2.4 Swing sealing plug for Clean Room robots and robots with food grade lubrication .149
4.3 Cable harness .................................................................................................. 153
4.3.1 Replacing the main cable package ............................................................. 153
4.3.2 Replacing the axis-4 FPC unit, housing extender unit and housing extender sealings
............................................................................................................. 222
4.3.3 Replacing the axis-5 FPC unit ................................................................... 253
4.3.4 Replacing the EIB/SMB unit ...................................................................... 265
4.4 Upper and lower arms ........................................................................................ 280
4.4.1 Replacing the lower arm .......................................................................... 280
4.4.2 Replacing the signal lamp ........................................................................ 343
4.4.3 Replacing the tubular spare parts .............................................................. 346
4.4.4 Replacing the axis-3 radial sealing and sealing ring ...................................... 379
4.4.5 Replacing the axis-2 mechanical stop ......................................................... 410
4.5 Swing and base ................................................................................................ 447
4.5.1 Replacing the base spare parts (base, axis-1 radial sealing, protection sleeve) ... 447
4.5.2 Replacing the swing spare parts (swing, axis-2 radial sealing) ........................ 522
4.6 Motors and gearboxes ....................................................................................... 588
4.6.1 Replacing the axis-1 gear unit .................................................................... 588
4.6.2 Replacing the axis-2 drive unit .................................................................. 589
4.6.3 Replacing the axis-3 drive unit .................................................................. 610
4.6.4 Replacing the axis-4 gearbox, drive shaft and pulley ..................................... 631
4.6.5 Replacing the axis-4 motor with pulley ....................................................... 673
4.6.6 Replacing the axis-4 timing belt ................................................................. 684
4.6.7 Replacing the axis-5 motor with pulley ....................................................... 699
4.6.8 Replacing the axis-5 timing belt ................................................................. 709
4.6.9 Replacing the axis-5 and axis-6 drive unit ................................................... 715
6 Product manual - IRB 1200

Table of contents
5 Calibration 737
5.1 Introduction to calibration ................................................................................... 737
5.1.1 Introduction and calibration terminology ...................................................... 737
5.1.2 Calibration methods ................................................................................. 738
5.1.3 When to calibrate ................................................................................... 740
5.2 Synchronization marks and axis movement directions ............................................. 741
5.2.1 Synchronization marks and synchronization position for axes ......................... 741
5.2.2 Calibration movement directions for all axes ................................................ 742
5.3 Updating revolution counters ............................................................................... 743
5.4 Calibrating with Axis Calibration method ............................................................... 746
5.4.1 Description of Axis Calibration .................................................................. 746
5.4.2 Calibration tools for Axis Calibration ........................................................... 749
5.4.3 Installation locations for the calibration tools ............................................... 752
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 754
5.5 Calibrating with manual calibration method ............................................................ 762
5.5.1 Manual calibration method - calibration position ............................................ 762
5.5.2 Manual calibration method - content of calibration toolkit 3HAC051256-001 ....... 763
5.5.3 Manual calibration method - calibrating axis 1 .............................................. 764
5.5.7 Manual calibration method - calibrating axis 5 and axis 6 ................................ 786
5.6 Verifying the calibration ...................................................................................... 790
5.7 Checking the synchronization position .................................................................. 791
6 Decommissioning 793
6.1 Introduction ...................................................................................................... 793
6.2 Environmental information .................................................................................. 794
6.3 Scrapping of robot ............................................................................................. 795
7 Robot description 797

7.1 Type A of IRB 1200 ........................................................................................... 797
7.2 Type B of IRB 1200 ........................................................................................... 798
7.3 Description of spare part versions ........................................................................ 799
7.3.1 Spare part versions for the base on IP40/IP67 robots ..................................... 799
7.3.2 Spare part versions for the swing on IP40/IP67 robots .................................... 801
7.3.3 Spare part versions for the axis-1 sealing ring on IP40/IP67 robots ................... 803
7.3.4 Spare part versions for the housing on Type A robots .................................... 804
7.3.5 Spare part versions for the tubular on Type A robots ..................................... 805
7.3.6 Spare part versions for the tubular cover on Clean Room robots ...................... 806
8 Reference information 807

8.1 Introduction ...................................................................................................... 807
8.2 Applicable standards ......................................................................................... 808
8.3 Unit conversion ................................................................................................. 810
8.4 Screw joints .................................................................................................... 811
8.5 Weight specifications ......................................................................................... 814
8.6 Standard toolkit ................................................................................................ 815
8.7 Special tools .................................................................................................... 816
8.8 Lifting accessories and lifting instructions .............................................................. 819
9 Spare parts 821

9.1 Spare part lists and illustrations ........................................................................... 821
10 Circuit diagrams 823

10.1 Circuit diagrams ................................................................................................ 823

Table of contents
Index 825

Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope

The manual covers covers all variants and designs of the IRB 1200. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety, service Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information on how to avoid
personal injuries and damage to the product.
Installation and commis- Required information about lifting and installation of the robot.
sioning
Maintenance Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Continues on next page

Continued
Chapter Contents
Calibration Calibration procedures and general information about calibration.
Decommissioning Environmental information about the robot and its components.
Reference information Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards, etc.
Spare parts and exploded Reference to the spare part list for the robot.
views
Circuit diagram 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
Operating manual - General safety information i 3HAC031045-001
Circuit diagram - IRB 1200 3HAC046307-003
Product manual - IRC5 3HAC021313-001
Product manual - IRC5 Compact 3HAC047138-001
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Technical reference manual - Lubrication in gearboxes 3HAC042927-001
Technical reference manual - System parameters 3HAC050948-001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
Revision Description
- First edition.

Continued
A Changes made in this revision:
• Information added about removal of axis-4 mechanical stop and
axis-4 FPC unit from housing extender unit, prior to replacing the
radial sealing at the housing extender unit. See Replacing the
axis-4 FPC unit, housing extender unit and housing extender
sealings on page 222.
• Information added about disconnecting and reconnecting the air
hoses at the tubular, when replacing the axis-4 timing belt. See
Replacing the axis-4 timing belt on page 684.
• Information added about removing screws that fasten the fix sheet
to the inner plastic guide inside housing, when removing axis-3
drive unit, see Creating space for separation of upper and lower
arm on page 615. Information also added about refitting the same
screws, throughout complete manual.
• Information added about releasing the holding brakes prior to ro-
tating axes manually, in calibration procedures, chapter Calibration
on page 737.
• Working range of axis 6 corrected from ±360° to ±400°, see
Working range on page 64.
• Information added about extra o-rings that are enclosed with the
robot at delivery, see Installation of extra O-ring on page 78 and
Installation of extra O-ring on page 103. Also added to repair pro-
cedures, where needed.
• Changed pin number for 24V connection, see Manually releasing
the brakes on page 74.

Continued
B Changes made in this revision:
• Information regarding how to read the procedures in this product
manual are updated, see How to read the product manual on
page 17.
• Information added about protection covers for water and dust
proofing, see Protection covers on page 52.
• Information added about transportation bracket that is used during
shipping and transport and must be removed before lifting the
robot, see Transportation bracket on page 53 and Attaching the
roundslings on page 69.
• Timing belt tension of axis-4 and axis-5 motors changed from 13
N and 15 N to 26 N and 30 N, respectively, in repair procedures,
chapter Repair on page 143.
• Tightening torque of M3 screws used on plastic materials changed
from 1.5 Nm to 0.3 Nm, in repair procedures, chapter Repair on
page 143.
• Total amount of harmonic grease 4B No.2 changed from 42 g to
32 g, see Replacing the axis-3 drive unit on page 610.
• Information added about checking PTFE film before refitting the
cable housing cover, see Replacing the EIB/SMB unit on page 265,
Replacing the axis-2 drive unit on page 589, Replacing the axis-3
drive unit on page 610, and Replacing the axis-4 timing belt on
page 684.
• No need to remove and refit cable bracket when removing and
refitting the cable package to the axis-1 sealing ring, see Replacing
the main cable package on page 153.
• No need to remove and refit connector plate when removing and
refitting the axis-5 motor with pulley, see Replacing the axis-4
FPC unit, housing extender unit and housing extender sealings
on page 222, Replacing the axis-4 gearbox, drive shaft and pulley
on page 631, Replacing the axis-5 motor with pulley on page 699.
• No need to remove and refit mechanical stop screw when remov-
ing the axis-4 mechanical stop, see Replacing the axis-4 mechan-
ical stop on page 416.
• Information modified about replacing motor bracket together with
motor flange when removing and refitting the axis-4 motor, see
Replacing the axis-4 gearbox, drive shaft and pulley on page 631
and Replacing the axis-4 motor with pulley on page 673.
• No need to remove tilt covers when replacing axis-5 drive unit,
see Replacing the axis-5 and axis-6 drive unit on page 715.

Continued
C Changes made in this revision
• Flange sealing changed from 12340011-116 Loctite 574 to
3HAC026759-002 Sikaflex-521FC for small cover on the housing,
see Replacing the axis-4 FPC unit, housing extender unit and
housing extender sealings on page 222.
• Tightening torque for attachment screws on lifting accessories is
changed from 40 Nm to 15 Nm.
• Tightening torque for lower arm cable
• Tightening torque for the axis-4 FPC unit attachment screws is
changed from 1.5 Nm to 0.3 Nm.
• Added a tightening torque for the attachment screws of the axis-
1 calibration stop pin and the axis-1 calibration pin.
• Added a caution note to keep a straight line when fitting the axis-
1 calibration pin.
• Article number of grease harmonic grease 4B No. 2 changed from
3HAC031695-001 to 3HAC037302-001.
• Total amount of harmonic grease 4B No.2 for axis 2 and axis 5
changed from 80 g and 12 g to 60 g and 9 g, respectively,
• Maximum revolution of axis 6 corrected to ±242°, see Working
range on page 66.
• Clean Room option added.
• Food grade lubrication option added.
• Spare part numbers for several gaskets (IP67) updated.
• The base, the swing and the axis-1 sealing ring are updated due
to IP67 improvements
D Published in release R16.2. The following updates are done in this revi-
sion:
• New standard calibration method introduced (Axis Calibration).
See Calibration on page 737.
• Information about grounding point is added, see Grounding and
bonding point on manipulator on page 103.
• Foundry Plus option added.
E Published in release R17.1. The following updates are done in this revi-
sion:
• A new standard IEC 61340-5-1:2010 added. See Applicable
standards on page 808.
• V-ring on axis-1 sealing ring version 3HAC058568-001 added as
a spare part.
• Notes added for spare part versions. See Description of spare
part versions on page 799.
• Information about Type B robots supporting SafeMove 2 added.
• Plug on base added to options IP67 and Foundry Plus.

Continued
F Published in release R17.2. The following updates are made in this revi-
sion:
• Caution about removing metal residues added in sections about
EIB/SMB boards.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Updated list of applicable standards.
• Article number for the Calibration tool box, Axis Calibration is
changed.
• Section Start of robot in cold environments on page 109 added.
• Tightening torque of screws securing the axis-5 and axis-6 drive
unit updated.
• Information about mechanically restricting the working range ad-
ded.
• Updated description about Clean Room class.
• Label added to remind the fitting of extra o-ring for robots with
protection class IP67 and with protection type Foundry Plus.
G Published in release R18.1. The following updates are made in this revi-
sion:
• Added sections in General procedures on page 144
• Safety section restructured.
• Note added to clarify the usage of the two M4 thread holes on the
upper arm.
• Added transportation bracket information for robots delivered with
a force control package.
• Updated extra o-ring fitting information for robots with protection
type Clean Room and robots with food grade lubrication.
• Note added to calibration chapter to emphasize the requirement
of equally dressed robot when using previously created reference
calibration values.
• Information about myABB Business Portal added.
• Spare part number of axis-4 gearbox shaft changed from
3HAC049631-001 to 3HAC044692-001.
H Published in release R18.2. The following updates are made in this revi-
sion:
• Added customer connection information.
• Spare part information about axis-2 drive unit and axis-3 drive
unit updated.
• Updated axis-4 and -5 timing belt inspection procedure.
• Added note for transportation bracket removal procedure.
J Published in release R18.2. The following updates are made in this revi-
sion:
• Updated references.

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals

The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.

Continued
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.

How to read the product manual
How to read the product manual

Reading the procedures
The procedures contain all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 19.
Illustrations
The product is illustrated with general figures that does not take painting or
protection type in consideration.
Likewise, certain work methods or general information that is valid for several
product models, can be illustrated with illustrations that show a different product
model than the one that is described in the current manual.

This page is intentionally left blank
1 Safety
1.1.1 Limitation of liability
1 Safety
1.1 General safety information
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Nation/region specific regulations

To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.
To be observed by the supplier of the complete system

The integrator is responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.

1 Safety
Continued
The integrator of the final application is required to perform an assessment of the

hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (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 robot.
Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered robot 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 of the robot could
be affected.

1 Safety
1.1.2 Protective stop and emergency stop
1.1.2 Protective stop and emergency stop
Overview
The protective stops and emergency stops are described in the product manual
for the controller.

1 Safety
1.2.1 Fire extinguishing
1.2 Safety actions
1.2.1 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the

manipulator or controller.

1 Safety
1.2.2 Emergency release of the robot axes
1.2.2 Emergency release of the robot axes
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
• Manually releasing the brakes on page 74.
The robot may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.
Increased injury
Before releasing the brakes, make sure that the weight of the robot does not
increase the pressure on the trapped person, further increasing any injury.
DANGER
When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways.
Make sure no personnel is near or beneath the robot.

1 Safety
1.2.3 Make sure that the main power has been switched off
1.2.3 Make sure that the main power has been switched off
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
personal injuries, switch off the main power on the controller before proceeding
work.
Note
Switch off all main power switches in a MultiMove system.

1 Safety
1.3.1 Safety risks during installation and service work on robots
1.3 Safety risks
Requirements on personnel
Only persons who know the robot and are trained in the operation and handling
of the robot are allowed to maintain the robot. Persons who are under the influence
of alcohol, drugs or any other intoxicating substances are not allowed to install,
maintain, repair, or use the robot.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install or service/maintain the robot must have the appropriate
training for the equipment in question and in any safety matters associated
with it.
• Personnel should be trained on responding to emergency or abnormal
situations.
General risks during installation and service

The instructions in the product manual must always be followed.
Never turn the power on to the robot before it is properly fixed and bolted to its
foundation/support.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
you are working with the system. A good method is to remove the power cable to
the controller.
If the robot is installed at a height, hanging, or other than standing directly on the
floor, there may be additional risks than those for a robot standing directly on the
floor.
Energy stored in the robot for the purpose of counterbalancing certain axes may
be released if the robot, or parts thereof, are dismantled.
Never use the robot as a ladder, which means, do not climb on the controller,
motors, or other parts during service work. There is a risk of slipping because of
the high temperature of the motors and oil spills that can occur on the robot. There
is also a risk of the robot being damaged.
To avoid damaging the product, make sure that there are no loose screws, turnings,
or other parts inside the product after work has been performed.
Safety risks during operational disturbances

Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.

1 Safety
Continued
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.
Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the robot and as a result of that affect
the active or passive safety operation. 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 robot.
Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface
for the connection of external safety devices. An external safety function can
interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment
for the installation.
Allergenic material
See Environmental information on page 794 for specification of allergenic materials
in the product, if any.

1 Safety
1.3.2 Moving robots are potentially lethal
1.3.2 Moving robots are potentially lethal
Description
Any moving robot is a potentially lethal machine.
When running, the robot may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may
seriously injure any personnel and/or damage any piece of equipment located
within the working range of the robot.
Safe handling
Action Note
1 Before attempting to run the robot, make Emergency stop equipment such as gates,
sure all emergency stop equipment is cor- tread mats, light curtains, etc.
rectly installed and connected.
2 Usually the hold-to-run function is active How to use the hold-to-run function is de-
only in manual full speed mode. To in- scribed in section How to use the hold-to-
crease safety it is also possible to activate run function in the Operating manual - IRC5
hold-to-run for manual reduced speed with with FlexPendant.
a system parameter.
The hold-to-run function is used in manual
mode, not in automatic mode.
3 Make sure no personnel are present within
the working range of the robot before
pressing the start button.

1 Safety
1.3.3 First test run may cause injury or damage
1.3.3 First test run may cause injury or damage
Description
After installation and performing service activities, there are several safety risks
to take into consideration before the first test run.
Safe handling
Use this procedure when performing the first test run after installation, maintenance,
or repair.
DANGER
Running the robot without fulfilling the following aspects, may involve a risk of
injury and cause severe damage to the robot.
Action
1 Remove all tools and foreign objects from the robot and its working area.
2 Verify that the robot is properly secured to its position by all screws, before it is powered
up.
3 Verify that any safety equipment installed to secure the position or restrict the robot
motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Install all safety equipment properly.
6 Make sure all personnel are standing at a safe distance from the robot, and is out of
its reach behind safety fences, or similar.
7 If maintenance or repair has been done, pay special attention to the function of the
part that was serviced.
Collision risks
CAUTION
When programming the movements of the robot, always identify potential collision
risks before the first test run.

1 Safety
1.3.4 Work inside the working range of the robot
1.3.4 Work inside the working range of the robot
WARNING
If work must be carried out within the work area of the robot, then the following
points must be observed:
• The operating mode selector on the controller must be in the manual mode
position to render the three-position enabling device operational and to block
operation from a computer link or remote control panel.
• The maximum speed of the robot is limited to 250 mm/s when the operating
mode selector is in the position Manual mode with reduced speed. This
should be the normal position when entering the working space.
The position Manual mode with full speed (100%) may only be used by
trained personnel who are aware of the risks that this entails. Manual mode
with full speed (100%) is not available in USA or Canada.
• Pay attention to the rotating axes of the robot. Keep away from axes to not
get entangled with hair or clothing. Also, be aware of any danger that may
be caused by rotating tools or other devices mounted on the robot or inside
the cell.
• Keep clear of moving parts so that limbs, hands, or fingers do not get trapped
or crushed by the robot.
• To prevent anyone else from taking control of the robot, always put a safety
lock on the cell door and bring the three-position enabling device with you
when entering the working space.
WARNING
NEVER, under any circumstances, stay beneath any of the robot's axes! There
is always a risk that the robot will move unexpectedly when robot axes are moved
using the three-position enabling device or during other work inside the working
range of the robot.

1 Safety
1.3.5 Enabling device and hold-to-run functionality
1.3.5 Enabling device and hold-to-run functionality
Three-position enabling device

The three-position enabling device is a manually operated, constant pressure
push-button which, when continuously activated in one position only, allows
potentially hazardous functions but does not initiate them. In any other position,
hazardous functions are stopped safely.
The three-position enabling device is of a specific type where you must press the
push-button only half-way to activate it. In the fully in and fully out positions,
operating the robot is impossible.
Note
The three-position enabling device is a push-button located on the teach pendant

which, when pressed halfway in, switches the system to MOTORS ON. When
the enabling device is released or pushed all the way in, the manipulator switches
to the MOTORS OFF state.
To ensure safe use of the teach pendant, the following must be implemented:
• The enabling device must never be rendered inoperational in any way.
• During programming and testing, the enabling device must be released as
soon as there is no need for the robot to move.
• Anyone entering the working space of the robot must always hold the teach
pendant. This is to prevent anyone else from taking control of the robot
without his/her knowledge.
Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. 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.

1 Safety
1.3.6 Risks associated with live electric parts
Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified
electrician in accordance with electrical regulations.
Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the main switch to
OFF) when repairing faults, disconnecting electric leads, and disconnecting or
connecting units.
The main supply to the robot must be connected in such a way that it can be turned
off from outside the working space of the robot.
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and robot during installation,
commissioning, and maintenance is guaranteed if the valid regulations are followed.
Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in
the controller.
• Units such as I/O modules, can be supplied with power from an external
source.
• The main supply/main switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)
• The drive unit (400/700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• 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.
Voltage related risks, manipulator

A danger of low voltage is associated with the manipulator in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max. 230
VAC).

1 Safety
Continued
Voltage related risks, tools, material handling devices, etc.

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.

1 Safety
1.3.7 The unit is sensitive to ESD
1.3.7 The unit is sensitive to ESD
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Safe handling
Action Note
1 Use a wrist strap. The wrist strap Wrist straps must be tested frequently to ensure
button is located inside the control- that they are not damaged and are operating cor-
ler. rectly.
• Product manual - IRC5 Compact
2 Use an ESD protective floor mat. The mat must be grounded through a current-limit-
ing resistor.
3 Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.

1 Safety
1.3.8 Hot parts may cause burns
1.3.8 Hot parts may cause burns
Description
During normal operation, many parts become hot. Touching these may cause
burns.
There is also a risk of fire if flammable materials are put on hot surfaces.
Safe handling
Always use your hand, at some distance, to feel if heat is radiating from the
potentially hot component before actually touching it.
Wait until the potentially hot component has cooled if it is to be removed or handled
in any other way.
Do not put anything on hot metal surfaces, e.g. paper or plastic.

1 Safety
1.3.9 Safety risks related to pneumatic/hydraulic systems
1.3.9 Safety risks related to pneumatic/hydraulic systems
General
Special safety regulations apply to pneumatic and hydraulic systems.
Note
All components that remain pressurized after separating the machine from the
power supply must be provided with clearly visible drain facilities and a warning
sign that indicates the need for pressure relief before adjustments or performing
any maintenance on the robot system.
Residual energy
Residual energy can be present in these systems. After shutdown, particular care
must be taken.
The pressure must be released in the complete pneumatic or hydraulic systems
before starting to repair them.
Work on hydraulic equipment may only be performed by persons with special
knowledge and experience of hydraulics.
All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.
Splashed oil may cause injury or fire.
Safe design
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.

1 Safety
1.3.10 Brake testing
1.3.10 Brake testing
When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be verified as described
below:
1 Run each robot axis to a position where the combined weight of the robot
arm and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the robot does not change position as the motors are switched off, then
the brake function is adequate.

1 Safety
1.3.11 Safety risks during handling of batteries
1.3.11 Safety risks during handling of batteries
Description
Under normal conditions of use, the electrode materials and liquid electrolyte in
the batteries are not exposed to the outside, provided the battery integrity is
maintained and seals remain intact.
There is a risk of exposure only in case of abuse (mechanical, thermal, electrical)
which leads to the activation of safety valves and/or the rupture of the battery
container. Electrolyte leakage, electrode materials reaction with moisture/water or
battery vent/explosion/fire may follow, depending upon the circumstances.
Note
Appropriate disposal regulations must be observed.
Safe handling
Use safety glasses when handling the batteries.
In the event of leakage, wear rubber gloves and chemical apron.
In the event of fire, use self-contained breathing apparatus.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Pre-installation procedure on page 57.

1 Safety
1.3.12 Safety risks during work with gearbox lubricants (oil or grease)
Description
When handling gearbox lubricants, there is a risk of both personal injury and
product damage occurring. The following safety information must be regarded
before performing any work with lubricants in the gearboxes.
Note
When handling oil, grease, or other chemical substances the safety information
of the manufacturer must be observed.
Note
When aggressive media is handled, an appropriate skin protection must be

provided. Gloves and goggles are recommended.
Note
Appropriate disposal regulations must be observed.
Note
Take special care when handling hot lubricants.
Safe handling
Warning Description Elimination/Action

Changing and draining gearbox Make sure that protective gear
oil or grease may require hand- like goggles and gloves are al-
ling hot lubricant heated up to ways worn during this activity.
90 °C.
Hot oil or grease
When working with gearbox lub- Make sure that protective gear
ricant there is a risk of an allergic like goggles and gloves are al-
reaction. ways worn.
Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox

1 Safety
Continued
Warning Description Elimination/Action

Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume
When draining the oil make sure
that as much oil as possible is
drained from the gearbox. The
reason for this is to drain as
much oil sludge and metal chips
as possible from the gearbox.
The magnetic oil plugs will take
Contaminated oil in care of any remaining metal
gear boxes chips.

1 Safety
1.4.1 Safety signals in the manual
1.4 Safety signals and symbols
Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the danger level (DANGER, WARNING, or CAUTION)
and the type of danger.
• A brief description of what will happen if the the danger is not eliminated.
• Instruction about how to eliminate danger to simplify doing the work.
Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol Designation Significance
DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height, and so on.
WARNING Warns that an accident may occur if the instructions
are not followed that can lead to serious injury, pos-
sibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height, etc.
ELECTRICAL Warns for electrical hazards which could result in
SHOCK severe personal injury or death.
CAUTION Warns that an accident may occur if the instructions

are not followed that can result in injury and/or
damage to the product. It also applies to warnings
of risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping, im-
pact, fall from height, etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.
ELECTROSTATIC Warns for electrostatic hazards which could result
DISCHARGE (ESD) in severe damage to the product.

1 Safety
Continued
Symbol Designation Significance

NOTE Describes important facts and conditions.
TIP Describes where to find additional information or

how to do an operation in an easier way.

1 Safety
1.4.2 Safety symbols on product labels
Introduction to labels
This section describes safety symbols used on labels (stickers) on the product.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The safety and health symbols on the labels on the product must be observed.
Additional safety information given by the system builder or integrator must also
be observed.
Types of labels
Both the manipulator and the controller are marked with several safety and
information labels, containing important information about the product. The
information is useful for all personnel handling the robot, for example during
installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 42.
The information labels can contain information in text (English, German, and
French).
Symbols on safety labels
Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.
xx0900000839

1 Safety
Continued
Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813
Before disassemble, see product manual
xx0900000816
Do not disassemble
Disassembling this part can cause injury.
xx0900000815
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000814
Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808

1 Safety
Continued
Symbol Description
Tip risk when loosening bolts
The robot can tip over if the bolts are not securely fastened.
xx0900000810
xx1500002402
Crush
Risk of crush injuries.
xx0900000817

1 Safety
Continued
Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)
xx0900000818
!
3HAC 4431-1/06
xx1300001087
Moving robot
4 6 The robot can move unexpectedly.
3 5
1
xx0900000819
xx1000001141
2 3
xx1500002616

1 Safety
Continued
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
Chain sling with shortener
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824

1 Safety
Continued
Symbol Description
No mechanical stop
xx1000001144
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.
xx0900000825
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
Do not step
Warns that stepping on these parts can cause damage to the
parts.
xx1400002648

2 Installation and commissioning
2.1 Introduction

2.1 Introduction
General
This chapter contains assembly instructions and information for installing the IRB
1200 at the working site.
More detailed technical data can be found in the Product specification for the IRB
1200, such as:
• Load diagram
• Permitted extra loads (equipment), if any
• Location of extra loads (equipment), if any.
Safety information
Before any installation work is commenced, it is extremely important that all safety
information is observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any installation
work.
Note
If the IRB 1200 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

2.2.1 Extra O-rings
2.2 Unpacking
2.2.1 Extra O-rings
Installation of extra O-rings

For robots with protection class IP67 (option 287-10)
For robots with protection type Foundry Plus (option 287-3)
For robots with protection type Clean Room (option 287-1)
For robots with food grade lubrication (option 777-1)
Two extra O-rings are delivered together with the robot and must be fitted to the
robot during installation.
Equipment Art. no. Note
O-ring 3HAB3772-19 For robots with protection class IP67
Used with protection type Foundry Plus
For robots with protection type Clean
Room
For robots with food grade lubrication
Used to seal between the main power
cable and the connector.
Robots with manipulator cables routed
from the rear of the base:
xx1500000243

from below (option 996-1):
xx1500000242

2.2.1 Extra O-rings
Continued

(option 287-10)
Room
Used with manipulator cables routed
from below (option 996-1)
xx1500000241
A label, showing in the following figure, is fitted on the connector to remind the
fitting of extra O-ring 3HAB3772-19. The label must be removed before the O-ring
and main cable is fitted.
Extra O-ring 3HAB3772-19 (delivered in

Accessories) for protection class IP67,
protection type Foundry Plus and Clean
Room must be fitted .
3HAC063211-001
xx1700001298
Further information
For installation information, see Orienting and securing the robot on page 77 and
Electrical connections on page 102.

2.2.2 Protection covers
2.2.2 Protection covers
Protection covers for water and dust proofing

A dust cap and two protectors (used with option 803-2) are delivered together with
the robot and must be well fitted to the connectors in any application requiring
water and dust proofing.
Dust cap 3HEA800897-002 Used to cover unused connectors for
water and dust proofing. Replace if
damaged.
M12 protector 3HAC047543-001 Used with option 803-2.
Used to cover unused connectors for
damaged.
RJ 45 protector 3HAC047539-001 Used with option 803-2.
Used to cover unused connectors for
damaged.
Protection covers for Foundry Plus robots

For robots with protection type Foundry Plus (option 287-3)
Extra protection covers, sealing and plugs are delivered together with Foundry
Plus robots and must be fitted to the robot during installation.
Protection bracket for 3HAC058350-001 Used with protection type Foundry Plus.
CP/CS connectors Replace if damaged.
Protection cover for axis- 3HAC044666-001 Used with protection type Foundry Plus.
6 turning disk Replace if damaged.
T40 variseal sealing 3HAC044641-012 Used with protection type Foundry Plus.
Replace if damaged.
Protection plug for lifting 3HAC4836-24 Used with protection type Foundry Plus.
holes Replace if damaged.

2.2.3 Transportation bracket
Location of the transportation bracket

A transportation bracket is installed and delivered together with the robot for
securing the robot position during shipping and transport. The transportation
bracket must be removed before fitting the lifting accessory to the robot during the
lifting of the robot to the installation site.
Note
If the robot is delivered with option 636-1 Force Control Package, the
transportation bracket is installed on the force sensor.
IRB 1200-7/0.7 IRB 1200-5/0.9

Without force control With force control package Without force control With force control package
package package
xx1800000002
xx1500001605 xx1800000003
xx1800000004
3HAC051896-001 3HAC064317-001 3HAC051897-001 3HAC064318-001
Removing the transportation bracket

Use this procedure to remove the bracket.
Note
The bracket must be kept for reuse after removal. Once robot shipping and
transportation are required, the transportation bracket has to be reinstalled for
securing the robot position.

Continued
Action Note
1 Move the robot to an appropriate position.
WARNING
The robot is likely to be mechanically unstable if

not secured to the foundation!
xx1500001399
2
CAUTION
For Clean Room robots, it is important not to rub

against the paint of the robot while performing
any service work on the robot.

Continued
Action Note
3 Remove the screws and washers.
CAUTION
Do not remove the force sensor if the robot is

delivered with a force control package.
xx1500001604
For robots delivered with force

control package
xx1800000005
4 Remove the bracket.

For robots with protection type Foundry Plus
(option 287-3)
Remove the two M10 rubber washers, as circled
in the figure, together with the bracket and reserve
them for further use.
xx1600001178
xx1500001400

Continued
Action Note
5 For robots with with protection type Clean Room Swing sealing plug: 3HAC053687-
For robots with food grade lubrication 001
Make sure the swing sealing plug is intact and the
sealant around fully covers the joint.
If not, replace the swing sealing plug and seal the
joint. See Swing sealing plug for Clean Room ro-
bots and robots with food grade lubrication on
page 149.
After the replacement, wipe clean.
xx1600000205
6 For robots with protection type Foundry Plus Protection plug for lifting holes:
Fit protection plugs to the lifting holes. 3HAC4836-24
xx1600001147

2.2.4 Pre-installation procedure
Introduction
This section is intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.
Prerequisites for installation personnel

Installation personnel working with an ABB product must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/maintenance/repair work
• conform to all national and local codes.
Checking the pre-requisites for installation
Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.
Note
Stop unpacking and contact ABB if transport damages are found.
4 Clean the unit with a lint-free cloth, if necessary.

5 Make sure that the lifting accessory used (if required) is suitable to handle the weight
of the robot as specified in: Weight, robot on page 57
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 60
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 60
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 58
• Protection classes, robot on page 61
• Requirements, foundation on page 59
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 67
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 69
11 Install required equipment, if any.
• Installing the signal lamp on page 92
Weight, robot
The table shows the weight of the robot.
Robot model Weight
IRB 1200 IRB 1200-5/0.9: 54 kg
IRB 1200-7/0.7: 52 kg

Continued
Note
The weight does not include tools and other equipment fitted on the robot.
Loads on foundation, robot

The illustration shows the directions of the robots stress forces.
The directions are valid for all floor mounted, suspended and inverted robots.
Txy
Fz
Fxy
Tz
xx1100000521
Fxy Force in any direction in the XY plane

Fz Force in the Z plane
Txy Bending torque in any direction in the XY plane
Tz Bending torque in the Z plane
The table shows the various forces and torques working on the robot during different
kinds of operation.
Note
These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
WARNING
The robot installation is restricted to the mounting options given in following load
table(s).
Floor mounted
Force Endurance load (in operation) Max. load (emergency stop)

Force xy ±910 N ±1620 N
Continued

Force z -550 ±980 N -550 ±1610 N
Torque xy ±570 Nm ±1550 Nm
Torque z ±280 Nm ±580 Nm
Wall mounted

Force xy ±1210 N ±1940 N
Force z 0 ±900 N 0 ±1340 N
Suspended

Force xy ±910 N ±1620 N
Force z +550 ±980 N +550 ±1610 N
Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.1/500 mm Flat foundations give better repeatability of the
surface resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
In order to compensate for an uneven surface,
the robot can be recalibrated during installation.
If resolver/encoder calibration is changed this
will influence the absolute accuracy.
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.

Continued
Requirement Value Note

Minimum resonance 22 Hz The value is recommended for optimal perform-
frequency ance.
Note Due to foundation stiffness, consider robot mass
including equipment. i
It may affect the For information about compensating for founda-
manipulator life- tion flexibility, see Application manual - Control-
time to have a ler software IRC5, section Motion Process Mode.
lower resonance
frequency than
recommended.
i The minimum resonance frequency given should be interpreted as the frequency of the robot
mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e.,
the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should
not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent
mass of the floor is very high, it will not affect robot movement, even if the frequency is well below
the stated 25 Hz. The robot should be mounted as rigid as possibly to the floor.
Disturbances from other machinery will affect the robot and the tool accuracy. The robot has
resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified,
although somewhat damped by the servo control. This might be a problem, depending on the
requirements from the applications. If this is a problem, the robot needs to be isolated from the
environment.
Storage conditions, robot

The table shows the allowed storage conditions for the robot:
Parameter Value
Minimum ambient temperature -25ºC
Maximum ambient temperature +55ºC
Maximum ambient temperature (less than 24 hrs) +70ºC
Maximum ambient humidity 95% at constant temperature
(gaseous only)
Operating conditions, robot

The table shows the allowed operating conditions for the robot:
Parameter Value
Minimum ambient temperature +5ºC i
Maximum ambient temperature +45ºC
Maximum ambient temperature for robots with food grade +35ºC ii
lubrication
Maximum ambient humidity 95% at constant temperature
i At low environmental temperature < 10ºC is, as with any other machine, a warm-up phase
recommended to be run with the robot. Otherwise there is a risk that the robot stops or run with
lower performance due to temperature dependent oil and grease viscosity.
ii For robots with food grade lubrication, if environment temperature > 35ºC, contact ABB for further
information.

Continued
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)
Manipulator, protection type Foundry Plus Not available
Manipulator, protection type Clean Room Not available

2.2.5 Dimensions
2.2.5 Dimensions
Dimensions IRB 1200-5/0.9
613
(A)
(B) 451 82
42
448
967
399,1
105 105
210 210
269
(C)
115
(D)
47
185 105
190 162
210
269,5
xx1400000339
Pos Description
A Minimum turning radius axis 4 R=79 mm
B Minimum turning radius axis 3 R=111 mm
C Minimum turning radius axis 1 R=138 mm
D Valid for option Robot cabling routing, 966-1 From below

2.2.5 Dimensions
Continued
Dimensions IRB 1200-7/0.7

530
(A) (B) 351 82
42
350
869
399,1
105 105
210 210
269
(C)
115
(D)
47
185 105
190 162
210
269,5
xx1300000366
Position Description
A Minimum turning radius axis 4 R=79 mm
B Minimum turning radius axis 3 R=139 mm
C Minimum turning radius axis 1 R=138 mm
D Valid for option Robot cabling routing, 966-1 From below

2.2.6 Working range
2.2.6 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
Z
Pos 0
1642
Pos 9
Pos 6
Pos 7 Pos 2 Pos 3
Pos 8
342
Pos 5 Pos 4
901 901
xx1300000387
Position in the Positions at wrist center (mm) Angle (degrees)

figure
X Z Axis 2 Axis 3
Pos0 451 889 0º 0º
Pos1 0 1300 0º -85º
Pos2 194 438 0º +70º
Pos3 901 402 +90º -85º
Pos4 692 -178 +130º -85º
Pos5 -179 -48 -100º -200º
Pos6 -72 583 -100º +70º
Pos7 -901 397 -90º -85º
Pos8 -887 240 -100º -85º
Pos9 458 549 +130° -200°

2.2.6 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
Z
Pos 0
Pos 6 Pos 9
1304
Pos 7 Pos 2
Pos 3
Pos 8
Pos 5
202
Pos 4
703 703
xx1300000386
Position in the Positions at wrist center (mm) Angle (degrees)

figure
X Z Axis 2 Axis 3
Pos0 351 791 0º 0º
Pos1 0 1102 0º -83º
Pos2 160 434 0º +70º
Pos3 703 398 +90º -83º
Pos4 497 -99 +135º -83º
Pos5 -133 55 -100º -200º
Pos6 -62 550 -100º +70º
Pos7 -703 400 -90º -83º
Pos8 -693 278 -100º -83º
Pos9 358 488 +135° -200°

2.2.6 Working range
Continued
Minimum turning radius of axis 1

170°
B (7/0.7)
B (5/0.9)
C (7/0.7)
C (5/0.9)
170°
xx1400000681
Robot variant Radius A Radius B Radius C

IRB 1200-5/0.9 138 mm i 901 mm 198 mm
IRB 1200-7/0.7 138 mm i 703 mm 163 mm
i Maximum turning radius of axis 1.
Working range
Axis Type of motion IRB 1200-7/0.7 IRB 1200-5/0.9

Axis 1 Rotation motion +170° to -170° +170° to -170°
Axis 2 Arm motion +135° to -100° +130° to -100°
Axis 3 Arm motion +70° to -200° +70° to -200°
Axis 4 Wrist motion +270° to -270° +270° to -270°
Axis 5 Bend motion +130° to -130° +130° to -130°
Axis 6 Turn motion Default: +400° to -400° Default: +400° to -400°
Maximum revolution: ±242 i Maximum revolution: ±242 i
i The default working range for axis 6 can be extended by changing parameter values in the software.
Option 610-1 Independent axis can be used for resetting the revolution counter after the axis has
been rotated (no need for "rewinding" the axis).

2.2.7 Risk of tipping/stability
Risk of tipping
If the robot is not fastened to the foundation while moving the arm, the robot is not
stable in the whole working area. Moving the arm will displace the center of gravity,
which may cause the robot to tip over.
The shipping position is the most stable position.
Do not change the robot position before securing it to the foundation!
Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.
xx1400000500
Transportation bracket
securing the robot position during shipping and transportation. The transportation
bracket must be removed before fitting the lifting accessory to the robot during the
lifting of the robot to the installation site.
For details, see Transportation bracket on page 53.

Continued
WARNING
The robot is likely to be mechanically unstable if not secured to the foundation.

2.3.1 Lifting robot with roundslings
2.3 On-site installation
Attaching the roundslings
Note
securing the robot position during shipping and transport. The transportation
bracket must be removed before fitting the lifting accessory to the robot during
the lifting of the robot to the installation site.
For details, see Transportation bracket on page 53.
xx1400000501
Required equipment
Equipment, etc. Article number Note

Overhead crane -

Continued

Roundsling, 0.6 m - 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.
Lifting and turning the robot with roundslings

Use this procedure to lift the robot with roundslings.
Action Note
1 Move the robot to an appropriate lifting posi-
tion.
WARNING
The robot is likely to be mechanically unstable

if not secured to the foundation!
xx1400000500
2
CAUTION
For Clean Room robots, it is important not to

rub against the paint of the robot while fitting
and lifting.
3 For robots with protection type Foundry Plus

(option 287-3)
Remove the protection plugs in lifting holes.
xx1600001147

Continued
Action Note
4 Fit the lifting tools to the robot. Lifting accessory, robot: 3HAC049711-
Use the enclosed screws. 001
(option 287-3)
Use two M10 rubber washers, as circled in the
figure, on the lifting holes at each side of the
robot (4 pcs in total) for protection when fitting
the lifting tools.
For robots with protection type Clean Room
Pay attention not to damage the swing sealing
plug and the sealant covering the joint when
fitting the lifting tools.
xx1400000498
Tightening torque: 15 Nm
For robots with protection type
Foundry Plus (option 287-3)
xx1600000205
Replace the swing sealing plug if damaged and

seal the joint. See Swing sealing plug for Clean xx1600001177
Room robots and robots with food grade lubric-
ation on page 149.
After the replacement, wipe clean.
5 Fit the roundslings to the lifting tools and attach Make sure the roundsling has free
them to the lifting beam. space and does not wear against any
part of the robot.
Roundsling, 1.5 m
xx1400000511

Continued
Action Note
6 Fit the roundslings to the lifting beam and to Roundsling, 0.6 m
the overhead crane.
xx1400000501
7
CAUTION
The IRB 1200 robot weighs .

IRB 1200-5/0.9: 54 kg
IRB 1200-7/0.7: 52 kg
All lifting accessories used must be sized ac-
cordingly!
8
WARNING
Personnel must not, under any circumstances,

be present under the suspended load!
9 Raise the overhead crane to lift the robot.

10 If the manipulator should be mounted on a wall,
or in an suspended position the manipulator
can now be tilted slowly by hand.
xx1600000005

2.3.2 Lifting and turning a suspended mounted robot
2.3.2 Lifting and turning a suspended mounted robot
Introduction
How to lift and turn the robot to a suspended position using the turning accessory
is described in the lifting instruction delivered with the turning accessory. Article
numbers for the accessory and the instruction is specified in Special tools on
page 816. Any additional equipment required is specified in the instruction for the
lifting accessory. Contact ABB for more information.
How to lift and turn the robot into position for wall position: Contact ABB for more
information.
How to lift and turn the robot into position for tilted position: Contact ABB for more
information.

2.3.3 Manually releasing the brakes
Introduction to 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

Continued
Releasing the brakes

This procedure details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
Action Note
1 The internal brake release unit is equipped with a
button for controlling the axes brakes.
If the robot is not connected to the controller,
power must be supplied to the connector R1.MP
according to the section Supplying power to con-
nector R1.MP on page 75.
xx1400000030
2
DANGER
When releasing the holding brakes, the robot axes

may move very quickly and sometimes in unexpec-
ted ways!
Make sure no personnel is near or beneath the
robot arm!
3 Release the holding brake on all robot axes by

pressing the button on the internal brake release
unit.
The brake will function again as soon as the button
is released.
Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector
R1.MP on the robot in order to enable the brake release buttons.
Action Note
1
DANGER
Incorrect connections, such as supplying

power to the wrong pin, may cause all
brakes to be released simultaneously!

Continued
Action Note
2 Supply +24V on pin 11 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

2.3.4 Orienting and securing the robot
Introduction
This section details how to orient and secure the robot to the foundation or base
plate in order to run the robot safely. The requirements made on the foundation
are shown in sections:
• Loads on foundation, robot on page 58
• Requirements, foundation on page 59.
Hole configuration, base

The illustration shows the hole configuration used when securing the robot.
+ 0,018
180
2x 6 H8 0
0.03 70
95
180
95
F
F
13,5
0.3
70
4x
16
F-F
xx1300000368

Continued
Specification, attachment screws and pins

The table specifies the type of securing screws and washers to be used to secure
the robot directly to the foundation. It also specifies the type of pins to be used.
Suitable screws M12x35 (robot installation directly on
foundation)
Quantity 4 pcs
Quality 8.8
Suitable washer 13 x 20 x 2, steel hardness class 300HV
Guide pins 2 pcs, D6x20, ISO 2338 - 6m6x20 - A1
Tightening torque 55 Nm ± 5 Nm
Level surface requirements
xx0900000643
Installation of extra O-ring

For robots with protection type FoundryPlus (option 287-3)
Manipulator cables routed from below (option 996-1)
The O-ring specified below is delivered together with the robot and must be installed
to the bottom of the base during installation.
(option 287-10)
Room
Used with manipulator cables routed
from below (option 996-1)
xx1500000241

Continued
Orienting and securing the robot

Use this procedure to orient and secure the robot.
Action Information
1 Make sure the installation site for the robot con-
forms to the specifications in section:
• Pre-installation procedure on page 57.
2 Prepare the installation site with attachment The hole configuration of the base
holes. is shown in the figure in:
• Hole configuration, base on
page 77
3
CAUTION
The robot weighs . All lifting equipment must be

sized accordingly!
IRB 1200-5/0.9: 54 kg
IRB 1200-7/0.7: 52 kg
4
CAUTION
When the robot is put down after being lifted or

transported, there is a risk of it tipping, if not
properly secured.
5 Lift the robot to its installation site. How to lift the robot is described in
section:
• Lifting robot with roundslings
on page 69
6 For robots with protection class IP67 (option
287-10)
(option 287-3)
(option 287-1)
For robots with food grade lubrication (option
777-1)
xx1500000241
Cabling routed from below (option 996-1)
Fit the O-ring 3HAB3772-141 to underneath the
robot base.
7 Fit two pins to the holes in the base. 2 pcs, D6x20, ISO 2338 - 6m6x20 -
A1
8 Guide the robot gently, using the attachment Make sure the robot base is cor-
screws while lowering it into its mounting posi- rectly fitted onto the pins.
tion.
9 Fit the securing screws and washers in the attach- Screws: M12x35 (robot installation
ment holes of the base. directly on foundation), quality: 8.8
10 Tighten the bolts in a criss-cross pattern to en- Tightening torque:
sure that the base is not distorted. 55 Nm ± 5 Nm

Continued
Action Information
11 For robots with protection class IP67 (option Robots with manipulator cables
287-10) routed from the rear of the base:
(option 287-3)
(option 287-1)
For robots with food grade lubrication (option
777-1)
Fit the O-ring 3HAB3772-19 to the main power
connector on the robot base.
xx1500000243
Robots with manipulator cables

routed from below (option 996-1):
xx1500000242
Securing robot on a mounting plate

When bolting a mounting plate or frame to a concrete floor, follow the general
instructions for expansion-shell bolts.
Screw joints must be able to withstand the stress loads defined in section Loads
on foundation, robot on page 58.

2.3.5 Setting the system parameters for a suspended or tilted robot
General
The robot is configured for mounting parallel to the floor, without tilting, on delivery.
The method for mounting the robot in a suspended (upside down) or tilted position
is basically the same as for floor mounting, but the system parameters that describe
the mounting angle (how the robot is oriented relative to the gravity) must be
re-defined.
Note
With suspended installation, make sure that the gantry or corresponding structure
is rigid enough to prevent unacceptable vibrations and deflections, so that
optimum performance can be achieved.
Note
The allowed mounting positions are described in the product specification for
the robot. The requirements on the foundation are described in Requirements,
foundation on page 59.
System parameters
Note
The mounting angle must be configured correctly in the system parameters so

that the robot system can control the movements in the best possible way. An
incorrect definition of the mounting angle will result in:
• Overloading the mechanical structure.
• Lower path performance and path accuracy.
• Some functions will not work properly, for example Load Identification and
Collision detection.
Gravity Beta
If the robot is mounted upside down or on a wall (rotated around the y-axis), then
the robot base frame and the system parameter Gravity Beta must be redefined.
Gravity Beta should then be π (+3.141593) if the robot is mounted upside down
(suspended), or ±π/2 (±1.570796) if mounted on a wall.
The Gravity Beta is a positive rotation direction around the y-axis in the base
coordinate system. The value is set in radians.
Gravity Alpha
If the robot is mounted on a wall (rotated around the x-axis), then the robot base
frame and the system parameter Gravity Alpha must be redefined. The value of
Gravity Alpha should then be ±π/2 (±1.570796).

Continued
The Gravity Alpha is a positive rotation direction around the x-axis in the base
coordinate system. The value is set in radians.
Note
The system parameter Gravity Alpha is not supported for all robot types. It is not
supported for IRB 140, IRB 1410, IRB 1600ID, IRB 2400, IRB 4400, IRB 6400R,
IRB 6400 (except for IRB 6400 200/2.5 and IRB 6400 200/2.8), IRB 6600, IRB
6650, IRB 6650S and IRB 7600 (except for IRB 7600 325/3.1).
If the robot does not support Gravity Alpha, then use Gravity Beta along with the
recalibration of axis 1 to define the rotation of the robot around the x-axis.
Note
The parameter is supported for all robots on track when the system parameter
7 axes high performance motion is set, see Technical reference manual - System
parameters.
Gamma Rotation
Gamma Rotation defines the orientation of the robot foot on the travel carriage
(track motion).
Mounting angles and values

The parameter Gravity Beta (or Gravity Alpha) specifies the mounting angle of the
robot in radians. It is calculated in the following way.
Gravity Beta = A° x 3.141593/180 = B radians, where A is the mounting
angle in degrees and B is the mounting angle in radians.
Example of position Mounting angle (A°) Gravity Beta

Floor mounted 0° 0.000000 (Default)
Tilted mounting 45° 0.785398
Wall mounting 90° 1.570796
Suspended mounting 180° 3.141593

Continued
Examples of mounting angles tilted around the Y axis (Gravity Beta)
xx1400000682
Pos 1 Floor mounted

Pos 2 Mounting angle 45° (Tilted)
Pos 3 Mounting angle 90° (Wall)
Pos 4 Mounting angle 180° (Suspended)

Continued
Examples of mounting angles tilted around the X axis (Gravity Alpha)

The following illustration shows the IRB 120, but the same principle applies for all
robots.
xx1500000532
Pos Mounting angle Gravity Alpha

1 0° (Floor mounted) 0
2 45° (Tilted) 0.785398
3 90° (Wall) 1.570796
4 -90° (Wall) -1.570796
Note
For suspended robots (180°), it is recommended to use Gravity Beta instead of

Gravity Alpha.

Continued
Defining the parameter in the IRC5 software

The value of the system parameters that define the mounting angle must be
redefined when changing the mounting angle of the robot. The parameters belong
to the type Robot, in the topic Motion.
How to calculate a new value is detailed in Mounting angles and values on page 82.
The system parameters are described in Technical reference manual - System
parameters.
The system parameters are redefined in the Configuration Editor, in RobotStudio
or on the FlexPendant.

2.3.6 Loads fitted to the robot, stopping time and braking distances
2.3.6 Loads fitted to the robot, stopping time and braking distances
General
Any loads mounted on the robot must be defined correctly and carefully (with
regard to the position of center of gravity and mass moments of inertia) in order
to avoid jolting movements and overloading motors, gears and structure.
CAUTION
Incorrectly defined loads may result in operational stops or major damage to the
robot.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must be defined in the software.
• Operating manual - IRC5 with FlexPendant
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.

2.3.7.1 Introduction to fitting of equipment
2.3.7 Fitting of equipment on the robot
2.3.7.1 Introduction to fitting of equipment
General
Extra loads can be mounted on to the upper arm. Definitions of load area and
permitted load are shown in figure below. The center of gravity of the extra load
shall be within the marked load areas. The robot is supplied with holes for fitting
of extra equipment. (See Holes for fitting extra equipment on page 88).
68
(A) (A)
216
216
150
68
34 (A)
IRB 1200-7/0.7
108
216
250
68
34
(A)
IRB 1200-5/0.9
108
216
xx1300000384
Load area (A) Max load

IRB 1200-5/0.9 0.3 kg
IRB 1200-7/0.7

2.3.7.2 Holes for fitting extra equipment
Upper arm
90 ±0,125
2 x M4 8
(A) 82
78
58
42
85
152
(B)
2 x M4 8
2xM5 7.5
20 ±0.125
30 ±0.15
xx1300000381
Pos Description
A IRB 1200-5/0.9 = 451 mm, IRB 1200-7/0.7 = 351 mm
B IRB 1200-5/0.9 = 216 mm, IRB 1200-7/0.7 = 116 mm

Continued
Note
The two M4 thread holes shown in the following figure are used for fitting the
cable harness or air hoses of the tools rather than fitting extra equipment.
2 x M4 8
xx1700002331
Lower arm
2 x M5 7.5
666,1
568,1
30 ±0,15
122,5 122,5 122,5 122,5

IRB 1200-7/0.7 IRB 1200-5/0.9
xx1300000382

Continued
Frame
30 ±0.15
2xM10 10
78 B
(A)
B
243
105
xx1400000590
Pos Description
A Holes on both sides
Robot tool flange + 0.021
+0.012
- 0.025
0
5 H7 0 6
0
0.04 6.5
20 H7
40 h7
J 4
4xM5 6
4x 90°
0.25
31.5 45° 5
J
J-J
xx1300000383

Continued
Robot tool flange for Foundry Plus robots

+ 0.012
5 H7 0 6
+ 0.021
40 h7 -0.025
0.04
0
E
4xM5 6 6.5
20 H7
0.25 4
4x 90°
31.5 E 45° 5
E-E
xx1600001322

2.4.1 Installing the signal lamp
2.4 Installation of options
General
A signal lamp with an yellow fixed light can be mounted on the robot, as a safety
device. The signal lamp is required on an UL/UR approved robot.
The lamp is active in MOTORS ON mode.
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

Continued
Required tools

Standard toolkit - Content is defined in section Standard
toolkit on page 815.
Installing the signal lamp
Action Note
1
DANGER
Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.
2
CAUTION
Always cut the paint with a knife and grind the paint
edge when disassembling parts. See Cut the paint
or surface on the robot before replacing parts on
page 144.
.
3 Remove the cover from the upper arm housing.
xx1300000464
4 Drill a hole with a diameter of 22.5 mm in the center

of the raised platform.
xx1300000465
5 Fit the lamp and tighten the nut.

6 Connect the two lamp cables connectors (R3.H1
and R3.H2) to the cable harness lamp connectors
(H1 and H2).

Continued
Action Note
7 Refit the cover on the upper arm housing. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm.
xx1300000456
Note
Only use specified screws, never

replace them with other screws.
8 Seal and paint the joints that have been opened.

See Cut the paint or surface on the robot before
replacing parts on page 144
Note
After all repair work, wipe the robot free from

particles with spirit on a lint free cloth.
9 The signal lamp is now ready for use and is lit in

MOTORS ON mode.

2.5.1 Axes with restricted working range
2.5 Restricting the working range
2.5.1 Axes with restricted working range
General
When installing the robot, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space
should be limited.
The working range of the following axes may be restricted:
• Axis 1, hardware (mechanical stop) and software. Note! The axis 1 stop is a
fixed stop that must be installed during operation of robot!
• Axis 5, hardware (mechanical stop) and software
• Axis 6, software
This section describes how to install hardware that restricts the working range.
Note
Adjustments must also be made in the robot configuration software (system

parameters). References to relevant manuals are included in the installation
procedures.

2.5.2 Mechanically restricting the working range
Location of mechanical stops

The figures shows where the mechanical stops are placed on the robot.
xx1700001293
A Mechanical stop axis 1 (swing)

B Mechanical stop axis 1 (base)

Continued
xx1700001294
A Mechanical stop axis 2 (lower arm)

B Mechanical stop axis 2 (swing)

Continued
xx1700001295
A Mechanical stop axis 3 (lower arm)

B Mechanical stop axis 3 (tubular)

Continued
xx1700001296
xx1700001297

Continued
The axis-1, axis-2, axis-3, and axis-4 stops are fixed stops that must be installed
during operation of robot. For details about how to install the stops, see:
• Replacing the axis-1 mechanical stop on page 585

2.6.1 Additional installation procedure, Clean Room
2.6 Making robot ready for operation
2.6.1 Additional installation procedure, Clean Room
General
Robots with protection type Clean Room are specially designed to work in a clean
room environment.
Clean Room robots are designed to prevent from particle emission from the robot.
For example, the maintenance work possible to perform without cracking the paint.
The robot is painted with four layers of polyurethane paint. The last layer being a
varnish over labels to simplify cleaning. The paint has been tested regarding
outgassing of Volatile Organic Compounds (VOC) and been classified in accordance
with ISO 14644-8.
Any Clean Room parts that are replaced must be replaced with parts designed for
use in Clean Room environments.
Clean Room class 3

According to IPA test result, the robot IRB 1200 is suitable for use in Clean Room
environment.
Classification of airborne molecular contamination
Parameter Outgassing amount

Area (m 2 ) Test dura- Temp (°C) Performed Total detec- Norm based Classifica-
tion (s) test ted (ng) on 1m 2 and tion in ac-
1s(g) cordance to
ISO 14644-
8
4.5E-03 3600 23 TVOC 2848 1.7E-07 -6.8
4.5E-03 60 90 TVOC 46524 1.7E-04 -3.8
Preparations before commissioning a Clean Room robot

During transport and handling of a Clean Room robot, it is likely that the robot has
been contaminated with particles of different kinds. Therefore the robot must be
carefully cleaned before installation.
Do not apply force on the plastic covers when lifting the robot! This may result in
damage or cracks in the paint around the plastic cover.

2.7.1 Robot cabling and connection points
2.7 Electrical connections
Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.
Main cable categories

All cables between the robot and controller are divided into the following categories:
Cable category Description
Robot cables Handles power supply to and control of the robot's motors
as well as feedback from the encoder interface board.
Specified in the table Robot cables on page 102.
Customer cables (option) Handles communication with equipment fitted on the robot
by the customer (low voltage signals).
The customer cables also handle Ethernet communication.
See the product manual for the controller, see document
number in References on page 10.
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet
to the robot motors.
Robot cable, signals Transfers encoder data from XS2 R1.EIB
and power supply to the en-
coder interface board.
Transfers resolver data from
and power supply to the serial
measurement board.
Robot cable, power
Power cable length Article number

3m 3HAC040503-007
7m 3HAC040503-001
15 m 3HAC040503-002
22 m 3HAC040503-003
30 m 3HAC040503-004
Robot cable, signals
Signal cable length Article number

3m 3HAC035320-001

Continued
Signal cable length Article number

7m 3HAC2493-1
15 m 3HAC2530-1
22 m 3HAC2540-1
30 m 3HAC2566-1
Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.
A
B
xx1600002016
A Diameter
B Diameter x10
Grounding and bonding point on manipulator

There is a grounding/bonding point on the manipulator base. The grounding/bonding
point is used for potential equalizing between control cabinet, manipulator and any
peripheral devices.
xx1600001081
Installation of extra O-ring

For robots with protection type FoundryPlus (option 287-3)

Continued
The O-ring specified below is delivered together with the robot and must be installed
to the main power connector during electrical installation.
Room
Used to seal between the main power
cable and the connector.
from the rear of the base:
xx1500000243

from below (option 996-1):
xx1500000242
Customer cables - CP/CS cable (option)
CP/CS cable length Article number

3 m (IRC5) 3HAC049089-001
7 m (IRC5) 3HAC049089-004
15 m (IRC5) 3HAC049089-005
22 m (IRC5) 3HAC049089-006
30 m (IRC5) 3HAC049089-007
3 m (IRC5C) 3HAC049186-001
7 m (IRC5C) 3HAC049186-004
15 m (IRC5C) 3HAC049186-005
22 m (IRC5C) 3HAC049186-006
30 m (IRC5C) 3HAC049186-007

Continued
Customer cables - Ethernet floor cable (option)
Ethernet floor cable length Article number

3m 3HAC055518-001
7m 3HAC055518-002
15 m 3HAC055518-003
22 m 3HAC055518-004
30 m 3HAC055518-005

2.7.2 Customer connections
Introduction to customer connections

The cables for customer connection are integrated in the robot and the connectors
are placed on the tubular housing (upper arm) and one at the base. There is one
connector R4.CP/CS at the tubular housing. Corresponding connector R1.CP/CS
is located at the base.
It is recommended to use a fuse protector for customer connection; otherwise,
application overload will burn out the CP/CS cables in the robot. Detailed information
about the CP/CS connection is provided in a warning label on the tubular housing.
xx1600001687
There is also connections for Ethernet, one connector R4.Ethernet at the tubular
housing and the corresponding connector R1.Ethernet located at the base.

Continued
Hose for compressed air is also integrated into the manipulator. There are 4 inlets
at the base (R1/8”) and 4 outlets (M5) on the tubular housing.
(C) (B)
(A)
(B)
(C)
(A)
xx1300000385
Position Connection Description Number Value

A (R1)R4.CP/CS Customer power/signal 10 49 V, 500 mA
B Air Max. 5 bar 4 Inner hose diameter 4 mm
C (R1)R4.Ethernet Customer Ethernet 8 100/10 Base-TX
Connectors
The tables describes the connectors on base and tubular housing (upper arm).
Connectors, base
Position Description Art. no.

Robot Pin connector 10p, bulkhead 3HAC022117-002
Customer connector Connector set R1.CP/CS 3HAC037038-001
Connectors, tubular housing

Robot Socket connector 10p, flange mounted 3HAC023624-002
Customer connector Connector set R3.CP/CS 3HAC037070-001

Continued
Air, connector

Robot 4xM5
Customer cable Air connector 3HAC032049-001

2.8 Start of robot in cold environments
2.8 Start of robot in cold environments
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
Problems with starting the robot

Event message from Motion Supervision
Use this procedure if an event message indicates a problem with Motion supervision
at start-up. More information about Motion Supervision is found in Technical
reference manual - System parameters.
Action Note
1 Turn off Motion Supervision.
2 Start the robot.
3 When the robot has reached normal working temper-
ature, the Motion Supervision can be turned on
again.
Robot stopping with other event message

Use this procedure if the robot is not starting.
Action Note
1 Start the robot with its normal program but The speed can be regulated with the
with reduced speed. RAPID instruction VelSet.
Adjusting the speed and acceleration during warm-up

Depending on how cold the environment is and what program is being used, the
speed might need to be ramped up until reached maximum. The table shows
examples of how to adjust the speed:
Work cycles AccSet Speed/velocity
3 Work cycles 20, 20 v100 (100 mm/s)
5 Work cycles 40, 40 v400 (400 mm/s)
5 Work cycles 60, 60 v600 (600 mm/s)
5 Work cycles 100, 100 v1000 (1000 mm/s)
More than 5 Work cycles 100, 100 Max.
If the program consists of large wrist movements, it is possible that the reorientation
velocity, which is always high in predefined velocities, needs to be included in the
ramping up.

3 Maintenance
3.1 Introduction
3 Maintenance
3.1 Introduction
Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB
1200.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided according to the
maintenance activity.
Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 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.

3 Maintenance
3.2.1 Specification of maintenance intervals
3.2 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.
• Operating time: specified in operating hours. More frequent running means
more frequent maintenance activities.

3 Maintenance
3.2.2 Maintenance schedule
Scheduled and non-predictable maintenance

The robot must be maintained regularly to ensure proper function. The maintenance
activities and intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages
must be attended to immediately!
Life of each component

The inspection intervals do not specify the life of each component.
Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals:
Maintenance activities Reference
Every 12 months
Every 36 months
Regularly i
Cleaning activities
Cleaning the robot x Cleaning the IRB 1200 on page 139
Inspection activities
Inspecting the robot x Check for abnormal wear or contam-
ination.
Room: Inspect daily
Inspecting the robot cabling ii x iii Inspecting the robot cabling on
page 115
Inspecting the information labels x Inspecting the information labels on
page 116
Inspecting the axis-1 mechanical stop x iv Inspecting mechanical stops on
pin page 121
page 121
page 121
Inspecting the axis-4 mechanical stop - v
Inspecting the timing belts x Inspecting timing belts on page 124
Replacement/changing activities

3 Maintenance
Continued
Every 12 months
Every 36 months
Regularly i
Replacing the battery pack vi Replacing the battery pack on
page 129
i "Regularly" implies that the activity is to be performed regularly, but the actual interval may not be
specified by the robot manufacturer. The interval depends on the operation cycle of the robot, its
working environment and movement pattern. Generally, the more contaminated environment, the
shorter intervals. The more demanding movement pattern (sharper bending cable harness), the
shorter intervals.
ii The robot cabling comprises the cabling between the robot and controller cabinet.
iii Replace when damage or cracks is detected or life limit is approaching.
iv Inspect immidiately if the mechanical stop is hit.
v Inspect immidiately if the mechanical stop is hit.
The robot needs to be disassembled according to section Replacing the axis-4 mechanical stop
on page 416 in order to get access to and inspect the mechanical stop.
vi The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. Typical life of a new battery is 36 months if the robot is
powered off 2 days/week, or 18 months if the robot is powered off 16 hours/day. The life can be
extended (approximately 3 times) for longer production breaks by a battery shutdown service
routine. See Operating manual - IRC5 with FlexPendant.
See the replacement instruction for more details.
Activities and intervals, optional equipment

The table below specifies the required maintenance activities and intervals:
Every 12 months
Inspection activities
Inspecting the signal lamp x Inspecting the signal lamp
(option) on page 127

3 Maintenance
3.3.1 Inspecting the robot cabling
3.3 Inspection activities
3.3.1 Inspecting the robot cabling
Introduction
CAUTION
Always read the specific instructions if the robot has protection type Clean Room,
before doing any repair work, see Cut the paint or surface on the robot before
Location of robot cabling

The robot cabling comprises the cabling between the robot and controller cabinet.
Required tools and equipment

Visual inspection, no tools are required.
Other tools and procedures may be required if the spare part needs to be replaced.
These are specified in the replacement procedure.
Inspection, robot cabling

Use this procedure to inspect the robot cabling.
Action Note
1
DANGER
Turn off all:

• electric power supply to the robot
• hydraulic pressure supply to the robot
• air pressure supply to the robot
Before entering the robot working area.
2 Visually inspect:
• the control cabling between the robot and
control cabinet
Look for abrasions, cuts or crush damages.
3 Replace the cabling if wear or damage is detected.

3 Maintenance
3.3.2 Inspecting the information labels
Location of labels
These figures show the location of the information labels to be inspected. The
symbols are described in section Safety symbols on product labels on page 42.
Illustration 1 of 2

 B
!
D
J
B
A
D B
Axis Resolver values

K
Absolute Accuracy
FOOD GRADE
ABB Robotics Products AB LUBRICATION
TYPE LABEL
Barcodes/Streckkod
H G
B B
CP/CS connection
B B
IRB 1200-7/0.7
B B
CP/CS connection
B B
IRB 1200-5/0.9

3 Maintenance
Continued
Illustration 2 of 2
$%% B
!
$%%
A A B
B
D
F E
UL lable
Lifting
instruction Warning
lable
IRB 1200-0.5/9
C B
B B
B
SECTION A-A VIEW B
IRB 1200 Option
Description Illustration
A Calibration label
B Warning label
Flash
xx1300001091

3 Maintenance
Continued
C Instruction label
Lifting of robot
xx1400000518
D Warning label
Heat
!
3HAC 4431-1/06
xx1300001087
29454489-16
xx1700000984
E Instruction label
Brake release
Moving robot !
Brake release buttons
3HAC 2577-1/ 04
xx1400000519
F UL label
G Rating label

3 Maintenance
Continued
H Warning label
Tip risk when loosening bolts
3HAC 037277-001
xx1400000527
J Clean Room label
xx1600001074
Foundry Plus label
xx1600001075


6XSSOHPHQWDU\GRFXPHQW 'RFW\SH 'RFXPHQW 'HVFULSWLRQ
3 Maintenance
Continued

6XSSOHPHQWDU\GRFXPHQW 'RFW\SH 'RFXPHQW 'HVFULSWLRQ
K Type A label
7<3($
:HUHVHUYHDOOULJKWVLQWKLVGRFXPHQWDQGLQWKHLQ
GLVFORVXUHWRWKLUGSDUWLHVZLWKRXWH[SUHVVDXWKRULW\
+$&
IRUPDWLRQFRQWDLQHGWKHUHLQ5HSURGXFWLRQXVHRU
LVVWULFWO\IRUELGGHQ$%%&RS\ULJKW
xx1600002136
Type B label
7<3(% )RQW$ULDO
&RORXU3ODWLQXPOLNH
0DWHULDO3(7 0RUHTXLYDOHQW
:HUHVHUYHDOOULJKWVLQWKLVGRFXPHQWDQGLQWKHLQ
GLVFORVXUHWRWKLUGSDUWLHVZLWKRXWH[SUHVVDXWKRULW\
+$&
IRUPDWLRQFRQWDLQHGWKHUHLQ5HSURGXFWLRQXVHRU
6HOIDGKHVLYH
LVVWULFWO\IRUELGGHQ$%%&RS\ULJKW
xx1600002137 ⷦ⇢$ULDO
欫唁村摠唁
㧟㠨3(7 0RUHTXLYDOHQW
卛槱呹伧
/DWHVW5HYLVLRQ
Required spare parts 1HZ
)RQW$ULDO
0DWHULDO7\SH 'LPHQVLRQ
&RORXU3ODWLQXPOLNH6:' 'UDZLQJ
'HVFULSWLRQ
Note 3UHSDUHG $SSURYHG

0DWHULDO3(7 0RUHTXLYDOHQW
6HOIDGKHVLYH
7\SH$/DEHO 6KHHW
)/LDQJ
6WDWXV 5HVSRQVLEOH'HSDUWPHQW 1RRIVK
,QUHYLHZ '052&150 ⷦ⇢$ULDO

The spare part numbers that are listed in the table can be out of date. See the (&21XPEHU
欫唁村摠唁
'RFXPHQWQR 5HYLQG
㧟㠨3(7 0RUHTXLYDOHQW

+$&
卛槱呹伧
latest revision of Product manual, spare parts - IRB 1200 on ABB Library. /DWHVW5HYLVLRQ
1HZ

0DWHULDO7\SH 'LPHQVLRQ 'HVFULSWLRQ 6:' 'UDZLQJ
Labels and plate set 3HAC051417-001 3UHSDUHG

Includes all safety and informa-
$SSURYHG
7\SH%/DEHO 6KHHW
)/LDQJ
6WDWXV tion labels required for the robot.
5HVSRQVLEOH'HSDUWPHQW 1RRIVK
,QUHYLHZ '052&150
Missing, damaged or illegable
(&21XPEHU 'RFXPHQWQR 5HYLQG
+$&

labels must be replaced.

Inspecting, labels
Action Note
1
DANGER
Turn off all:

2 Inspect the labels, located as shown in the figures.

3 Replace any missing or damaged labels. Article numbers for the labels and
plate set is specified in Spare
parts on page 821.

3 Maintenance
3.3.3 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

3 Maintenance
Continued
Axis 3
xx1400000386
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.

Mechanical stop set, axis 1 3HAC049630-001 Includes mechanical stop pin (1
pc), washer and screw.
pc) and screws.
pc) and screws.

Other tools and procedures may be required if the spare part needs to be replaced.
These are specified in the replacement procedure.

3 Maintenance
Continued
Inspecting mechanical stops

Use this procedure to inspect mechanical stops on axes 1, 2 and 3.
Action Information
1
DANGER
Turn off all:

2 Inspect the mechanical stops. See the figures in:

• Location of mechanical
stops on page 121
3 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.

3 Maintenance
3.3.4 Inspecting timing belts
Introduction
CAUTION
Always read the section "General procedures" befor doing any repair work.
Cut the paint or surface on the robot before replacing parts on page 144
Location of timing belts

The timing belts are located as shown in the figures.
Axis 4
xx1400000036

3 Maintenance
Continued
Axis 5
xx1400000032
Equipment Note
Standard toolkit The content is defined in the section Stand-
ard toolkit on page 815.
Other tools and procedures may be required
if the spare part needs to be replaced. These
are specified in the replacement procedure.
Inspecting timing belts

Use this procedure to inspect timing belts.
Action Information
1
DANGER
Turn off all:

to the robot, before entering the robot
working area.
2 Gain access to each timing belt by removing

the cover.
3 Check the timing belts for damage or wear.
4 Check the timing belt pulleys for damage.
5 If any damage or wear is detected, the part
must be replaced!

3 Maintenance
Continued
Action Information
6 Check whether timing belts are slack
manually.
If the belt has no tension, adjust it!

3 Maintenance
3.3.5 Inspecting the signal lamp (option)

The signal lamp is located as shown in this figure.
xx1300000455
Equipment Article number Note

Signal lamp kit See Spare parts on To be replaced if damage is detected.
page 821.
Standard toolkit - Content is defined in section Stand-
ard toolkit on page 815.
Inspecting, signal lamp

Use this procedure to inspect the function of the signal lamp.
Action Note
1 Inspect that signal lamp is lit when motors are put in
operation ("MOTORS ON").

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

3 If the lamp is not lit, trace the fault by: Article number is specified in Re-
• inspecting whether the signal lamp is broken. quired tools and equipment on
If so, replace it. page 127.
• inspecting cable connections.
• inspecting the cabling. Replace the cabling if
a fault is detected.

3 Maintenance
3.4.1 Replacing the battery pack
3.4 Replacement/changing activities
Note
The battery low alert (38213 Battery charge low) is displayed when remaining
backup capacity (robot powered off) is less than 2 months. Typical life of a new
battery is 36 months if the robot is powered off 2 days/week, or 18 months if the
robot is powered off 16 hours/day. The life can be extended (approximately 3
times) for longer production breaks by a battery shutdown service routine. See
Operating manual - IRC5 with FlexPendant.
Location of battery pack

The battery pack is located as shown in the figure.
xx1300002574
Note

3 Maintenance
Continued

Battery pack 3HAC051036-001 Battery includes protection cir-
cuits. Only replace with a spe-
cified spare part or an ABB-ap-
proved equivalent.
Battery pack, SafeMove 2-sup- 3HAC044075-001 Used for IRB 1200 Type B. See
ported Type B of IRB 1200 on page 798.
Battery includes protection cir-
cuits. Only replace with a spe-
cified spare part or an ABB-ap-
proved equivalent.
Gasket on EIB/SMB cover 3HAC056728-001 Not used with protection class
IP40.
Replace if damaged.

24 VDC power supply - Used to release the motor brakes.
CAUTION
Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 144.
Required consumables
Consumable Article number Note
Cable straps -
Removing the battery pack

Use this procedure to remove the battery pack.
Preparations before removing the battery pack
Action Note
1 Move the robot to its zero position. This is done in order to facilitate updating
of the revolution counter.
2
DANGER
Turn off all:

working area.

3 Maintenance
Continued
Removing the battery pack

Action Note
1
DANGER
Make sure that all supplies for electrical power,

hydraulic pressure, and air pressure are turned
off.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the

unit please read the safety information in the
section The unit is sensitive to ESD on page 33
3
CAUTION
Always cut the paint with a knife and grind the

paint edge when disassembling parts. See Cut
the paint or surface on the robot before replacing
parts on page 144.
.
4 Remove the connector cover attachment screws
on the lower arm and carefully open the cover.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
CAUTION
Be aware of the cabling that is attached to the

cover!
xx1300002427
5 Valid for IRB 1200 (no type specified) and IRB

1200 Type A
Disconnect the connectors on the EIB unit.
• R1.ME1-3
• R1.ME4-6
• R2.EIB
xx1400000812

3 Maintenance
Continued
Action Note
6 Valid for IRB 1200 Type B
Loose the connector screws.
xx1700000004

Disconnect the connectors on the SMB unit.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
xx1700000005

3 Maintenance
Continued
Action Note
8 Disconnect the battery cable. Valid for IRB 1200 (no type spe-
cified) and IRB 1200 Type A
xx1300002571
Valid for IRB 1200 Type B
xx1700000006

3 Maintenance
Continued
Action Note
9 Cut the cable strap that secures the battery and Valid for IRB 1200 (no type spe-
remove the battery. cified) and IRB 1200 Type A
Note
Battery includes protection circuits. Only replace

with a specified spare part or with an ABB- ap-
proved equivalent.
xx1300002579
xx1700000007
Refitting the battery pack

Use these procedures to refit the battery pack.
Refitting the battery pack

Action Note
1


3 Maintenance
Continued
Action Note
2
CAUTION

parts on page 144.
.
3 Fit the battery and and secure it with a cable strap. Valid for IRB 1200 (no type spe-
Note
Battery includes protection circuits. Only replace

with a specified spare part or with an ABB- ap-
proved equivalent.
xx1300002579
xx1700000007

3 Maintenance
Continued
Action Note
4 Connect the battery cable. Valid for IRB 1200 (no type spe-
xx1300002571
xx1700000006
5 Valid for IRB 1200 (not type specified) and IRB

1200 Type A
Connect the connectors to the EIB unit.
• R1.ME1-3
• R1.ME4-6
• R2.EIB
WARNING
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.
xx1400000812

3 Maintenance
Continued
Action Note
Connect the connectors to the SMB unit.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING
Make sure not to mix the R2.SMB and R2.ME2.

xx1700000005
7 Valid for IRB 1200 Type B Tightening torque: 0.3 Nm

Tighten the connector screws.
xx1700000004
8 Refit the EIB/SMB cover to the lower arm with the Screws: 3HAB3409-207 (M3x8).
attachment screws. Tightening torque: 1.5 Nm
xx1300002427
Note


3 Maintenance
Continued
Action Note
Note

Concluding procedure
Action Note
1 Update the revolution counters. See Updating revolution counters on
page 743.
2
CAUTION
Always cut the paint with a knife and grind

the paint edge when disassembling parts.
See Cut the paint or surface on the robot
before replacing parts on page 144.
.
Note
After all repair work, wipe the Clean Room

robot free from particles with spirit on a lint
free cloth.
3
DANGER
Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section First test
run may cause injury or damage on
page 28.

3 Maintenance
3.5.1 Cleaning the IRB 1200
3.5 Cleaning activities
WARNING
Turn off all electrical power supplies to the manipulator before entering its work
space.
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 product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 1200.
Note
Always verify the protection type of the robot before cleaning.
Special cleaning considerations

This section specifies some special considerations when cleaning the robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning.
• Never point the water jet at connectors, joints, sealings, or gaskets.
• Do not use compressed air to clean the robot.
• Never use solvents that are not approved by ABB to clean the robot.
• Do not spray from a distance closer than 0.4 m.
• Do not remove any covers or other protective devices before cleaning the
robot.
Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.
Protection Cleaning method
type
Vacuum Wipe with cloth Rinse with water High pressure water or
cleaner steam
Standard Yes Yes. With light No No
IP40 cleaning deter-
gent.

3 Maintenance
Continued
Protection Cleaning method

type
Vacuum Wipe with cloth Rinse with water High pressure water or
cleaner steam
IP67 (option) Yes Yes. With light Yes. It is highly re- No
cleaning deter- commended that
gent. the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
Foundry Plus Yes Yes. With light Yes. It is highly re- Yes i .
cleaning deter- commended that It is highly recommended
gent or spirit. the water contains that the water and steam
a rust-prevention contains rust preventive,
solution. without cleaning deter-
gents.
Clean room Yes Yes. With light No No
cleaning deter-
gent, spirit or
isopropyl alco-
hol.
i Perform according to section Cleaning with water and steam on page 140.
Wiping with cloth

Additional cleaning instructions for robots with food grade lubrication
Make sure that no liquid flows into the robot or stagnates in any gap or surface
after cleaning.
Cleaning with water and steam

Instructions for rinsing with water
IRB 1200 with protection class IP67 (option) and with protection type Foundry Plus
can be cleaned by rinsing with water (water cleaner). 1
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I
• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum flow: 20 liters/min I
I Typical tap water pressure and flow
Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be
cleaned using a steam cleaner or high pressure water cleaner. 2
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 2500 kN/m 2 (25 bar)
• Fan jet nozzle should be used, min. 45° spread
• Minimum distance from nozzle to encapsulation: 0.4 meters
1 See Cleaning methods on page 139 for exceptions.

2 See Cleaning methods on page 139 for exceptions.

3 Maintenance
Continued
• Maximum water temperature: 80° C
Cables
Movable cables need to be able to move freely:
• Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
• Clean the cables if they have a crusty surface, for example from dry release
agents.

4 Repair
4.1 Introduction
4 Repair
4.1 Introduction
Structure of this chapter

This chapter describes all repair activities recommended for the IRB 1200 and any
external unit.
It is made up of separate procedures, each describing a specific repair activity.
Each procedure contains all the information required to perform the activity, for
example spare parts numbers, required special tools, and materials.
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Otherwise damage to the mechanics and electronics may occur.
Required equipment
The details of the equipment required to perform a specific repair activity are listed
in the respective procedures.
The details of equipment are also available in different lists in the chapter Reference
information on page 807.
Safety information
There are general safety information and specific safety information. The specific
safety information describes the danger and safety risks while performing specific
steps in a procedure. Make sure to read through the chapter Safety on page 19
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.

4 Repair
4.2.1 Cut the paint or surface on the robot before replacing parts
4.2 General procedures
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
When replacing parts on a robot with protection type Clean Room, it is important
to make sure that after the replacement, no particles will be emitted from the joint
between the structure and the new part, and that the easy cleaned surface is
retained.
Required equipment
Equipment Spare parts Note

Sealing compound Sikaflex 521 FC. Color white.
Tooling pin Width 6-9 mm, made of wood.
Cleaning agent Ethanol
Knife
Lint free cloth
Touch up paint Clean Room, 3HAC036639-001
White
Removing
Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
xx0900000121
2 Carefully grind the paint edge that is left on

the structure to a smooth surface.
Refitting
Note
Refitting is required only for robots with protection type Clean Room.

4 Repair
Continued
Action Description
1 Before the parts are refitted, clean the joint Use ethanol on a lint free cloth.
so that it is free from oil and grease.
2 Place the tooling pin in hot water.
3 Seal all refitted joints with Sikaflex 521FC.
xx0900000122
4 Use the tooling pin to even out the surface

of the Sikaflex seal.
xx0900000125
5 Wait 15 minutes. Sikaflex 521FC skin dry time (15 minutes).

6 Use Touch up paint Clean Room, white to 3HAC036639-001
paint the joint.
Note
Always read the instruction in the product

data sheet in the paint repair kit for Clean
Room.
Note
After all repair work, wipe the robot free from particles with spirit on a lint free
cloth.

4 Repair
4.2.2 Mounting instructions for seals
General
This section describes how to mount different types of seals.
Equipment

Grease 3HAB3537-1 Used to lubricate the seals.
Grease 3HAC043771-001 Used to lubricate the seals of
robots with food grade lubric-
ation.
Rotating seals
The procedure below describes how to fit rotating seals.
CAUTION
Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.
• Keep the seal in its original wrappings or protect it well before actual
mounting.
• The fitting of seals and gears must be carried out on clean workbenches.
• Use a protective sleeve for the sealing lip during mounting, when sliding
over threads, keyways, etc.
Action Note
1 Check the seal to ensure that:
• The seal is of the correct type (provided with cutting
edge).
• There is no damage to the sealing edge (feel with a
fingernail).
2 Inspect the sealing surface before mounting. If scratches
or damage are found, the seal must be replaced since it
may result in future leakage.
3 Lubricate the seal with grease just before fitting. (Not too Article number is specified
early - there is a risk of dirt and foreign particles adhering in Equipment on page 146.
to the seal.)
Fill 2/3 of the space between the dust tongue and sealing
lip with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4 Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.
5 Make sure no grease left on the robot surface.

4 Repair
Continued
Flange seals and static seals

The following procedure describes how to fit flange seals and static seals.
Action
1 Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
2 Clean the surfaces properly in accordance with the recommendations of ABB.
3 Distribute the sealing compound evenly over the surface, preferably with a brush.
4 Tighten the screws evenly when fastening the flange joint.
O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.
3 Check the o-ring grooves. Defective o-rings may not be used.
The grooves must be geometrically correct and
should be free of pores and contamination.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Make sure that no grease is left on the robot
surface.

4 Repair
4.2.3 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.
This means that there are differences in the repair procedures depending on the
robot protection class. These are clearly stated in the step-by-step procedures.

4 Repair
4.2.4 Swing sealing plug for Clean Room robots and robots with food grade lubrication
4.2.4 Swing sealing plug for Clean Room robots and robots with food grade
lubrication
Location of the swing sealing plug

The swing sealing plug is located as shown in the figure.
xx1600000264
Note

Swing sealing plug 3HAC053687-001 Used with protection type Clean
Room.
Used for robots with food grade
lubrication.
Replace if damaged.


4 Repair
Continued
Consumable Art. no. Note
Sealant 3HAC026759-001 Sikaflex 521FC
Clean Room
Removing the swing sealing plug
Action Note
1 Cut the swing sealing plug through with a sharp
object to get access to the screws.
xx1600000206
2 Remove the cable housing cover of the swing by

removing the screws.
xx1600000207
3 Detach the swing sealing plug from the cable

housing cover.
xx1600000208

4 Repair
Continued
Refitting the swing sealing plug
Action Note
1 Mask the gap between the swing and the base.
xx1600000209
2 Apply a string of the sealant Sikaflex 521FC to

the joint of the swing cable housing cover.
xx1600000210
3 Smooth out the sealant string using a finger tip.

Use washing-up on finger tips to get a smooth
joint. If necessary, add extra sealant to get a full
cover joint. Make sure the sealant fully covers the
gap but is not applied to the screw cavities.
4 Wait at least 30 minutes for Sikaflex 521FC to dry Sikaflex 521FC skin dry time: 30
and then remove the mask. minutes
5 Apply a little sealant Sikaflex 521FC to the inner
surface of the swing sealing plug.
xx1600000211
xx1600000261

4 Repair
Continued
Action Note
6 Refit the swing sealing plug.
xx1600000212
7 If there is any overflowing sealant, remove and

clean it.
Make sure no space exists between the swing
sealing plug and the robot casting, and the sealant
string is fully jointed with the plug.
xx1600000213

4 Repair
4.3.1 Replacing the main cable package
4.3 Cable harness
Location of the main cable package

The main cable package runs from the base, up through the swing, up through the
lower arm and into the housing. Inside the housing there is a division point for the
axis-5 and axis-6 motor cables.
The main cable package includes the air hoses and the cabling for all the six motors.
Optional Ethernet cabling can also be included.
The air hoses and optional Ethernet must be disconnected inside the wrist unit
before the cable package can be removed.
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

4 Repair
Continued
Connector interface at the bottom of the base (option)
xx1400000410
Note

Manipulator cable harness with 3HAC059673-001 With connector interface at rear
Ethernet (rear interface) of the base.
Manipulator cable harness 3HAC059674-001 With connector interface at rear
without Ethernet (rear interface) of the base.
Manipulator cable harness with 3HAC056219-001 Used with protection type Clean
Ethernet (rear interface), Clean Room.
Room Used for robots with food grade
Manipulator cable harness with lubrication.
Ethernet (rear interface), food With connector interface at rear
grade lubrication of the base.

4 Repair
Continued

Manipulator cable harness 3HAC056220-001 Used with protection type Clean
without Ethernet (rear interface), Room.
Clean Room Used for robots with food grade
Manipulator cable harness lubrication.
without Ethernet (rear interface), With connector interface at rear
food grade lubrication of the base.
Manipulator cable harness with 3HAC051415-001 With connector interface at bot-
Ethernet (bottom interface) tom of the base.
Manipulator cable harness 3HAC051416-001 With connector interface at bot-
without Ethernet (bottom inter- tom of the base.
face)
Manipulator cable harness with 3HAC061282-001 Used for IRB 1200 Type B. See
Ethernet (rear interface), Safe- Type B of IRB 1200 on page 798.
Move 2-supported With connector interface at rear
of the base.
Manipulator cable harness 3HAC061283-001 Used for IRB 1200 Type B. See
without Ethernet (rear interface), Type B of IRB 1200 on page 798.
SafeMove 2-supported With connector interface at rear
of the base.
Ethernet (rear interface), Clean Type B of IRB 1200 on page 798.
Room and SafeMove 2-suppor- Used with protection type Clean
ted Room.
Manipulator cable harness with Used for robots with food grade
Ethernet (rear interface), food lubrication.
grade lubrication and SafeMove
2-supported With connector interface at rear
of the base.
without Ethernet (rear interface), Type B of IRB 1200 on page 798.
Clean Room and SafeMove Used with protection type Clean
2-supported Room.
Manipulator cable harness Used for robots with food grade
without Ethernet (rear interface), lubrication.
food grade lubrication and
SafeMove 2-supported With connector interface at rear
of the base.
Ethernet (bottom interface), Type B of IRB 1200 on page 798.
SafeMove 2-supported With connector interface at bot-
tom of the base.
without Ethernet (bottom inter- Type B of IRB 1200 on page 798.
face), SafeMove 2-supported With connector interface at bot-
tom of the base.
Cable harness material set 3HAC049663-001 Includes brackets, sheets, dis-
tance screws, plastics, cable
clamp, seal bolts and air protec-
tion in tubular.
Air connector set with Ethernet 3HAC049664-001 Includes tubular flange, air con-
hole in flange nectors and seal bolts.
Replace if damaged.

4 Repair
Continued

Air connector set without Ether- 3HAC049665-001 Includes tubular flange, air con-
net hole in flange nectors and seal bolts.
Replace if damaged.
Base bottom cover (standard 3HAC049667-001 Replace if damaged.
configuration)
Base rear cover, without connect- 3HAC059675-001 Replace if damaged.
or interface
Base rear cover, without connect- 3HAC056147-001 Used with protection type Clean
or interface, Clean Room Room.
Base rear cover, without connect- Used for robots with food grade
or interface, food grade lubrica- lubrication.
tion Replace if damaged.
Gasket for rear base cover 3HAC058566-001 Not used with protection class
IP40.
Replace if damaged.
O-ring 3HAB3772-86 Not used with protection class
IP40.
Replace if damaged.
Radial sealing with dust lip 3HAB3701-47 Not used with protection class
IP40.
Replace if damaged.
M2 variseal sealing 3HAC044641-002 Used with protection class IP67.
Used only on base
3HAC049628-001. See Spare
part versions for the base on
IP40/IP67 robots on page 799.
Replace if damaged.
Axis-1 sealing ring 3HAC044676-001 / Replace if damaged.
3HAC058568-001 i
V-ring 3HAB3732-34 Used with protection class IP67.
Used with protection type
Foundry Plus.
Only on swing version
3HAC058000-001 and
part versions for the swing on
Replace if damaged.
Axis-2 sealing ring 3HAC044677-001 Replace if damaged.
Gasket of axis-2 sealing ring 3HAC045688-001 Not used with protection class
IP40.
Replace if damaged.
IP40.
Replace if damaged.
Gasket of plastic plate 3HAC044894-001 Not used with protection class
IP40.
Replace if damaged.
Cable protection 3HAC044691-001 Replace if damaged.

4 Repair
Continued

Torx countersunk head screw 3HAC14286-4 Replace if damaged.
M3x5
Cover on top of swing 3HAC059679-001 Replace if damaged.
Cover on top of swing, Clean 3HAC056133-001 Used with protection type Clean
Room Room.
Cover on top of swing, food Used for robots with food grade
grade lubrication lubrication.
Replace if damaged.
Gasket on top swing cover 3HAC056696-001 Not used with protection class
IP40.
Replace if damaged.
Foundry Plus.
Replace if damaged.
Cable housing cover of the 3HAC059678-001 Replace if damaged.
swing
Cable housing cover of the 3HAC056214-001 Used with protection type Clean
swing, Clean Room Room.
Cable housing cover of the Used for robots with food grade
swing, food grade lubrication lubrication.
Replace if damaged.
Gasket on cable housing cover 3HAC056726-001 Not used for robots with protec-
tion class IP40.
Replace if damaged.
PTFE film on cable housing 3HAC044660-001 Replace if damaged.
cover
Gasket on cable housing cover 3HAC056724-001 Not used with protection class
IP40.
Replace if damaged.
EIB/SMB cover 3HAC059692-001 Replace if damaged.
EIB/SMB cover, Clean Room 3HAC056137-001 Used with protection type Clean
EIB/SMB cover, food grade lub- Room.
rication Used for robots with food grade
lubrication.
Replace if damaged.
IP40.
Replace if damaged.
Motor bracket 3HAC044689-001 Replace if damaged.
Housing small cover 3HAC059684-001 Replace if damaged.
Housing small cover, Clean 3HAC056142-001 Used with protection type Clean
Room Room.
Housing small cover, food grade Used for robots with food grade
lubrication lubrication.
Replace if damaged.

4 Repair
Continued

IP40.
Replace if damaged.
Gasket for tubular cover 3HAC058822-001 Not used with protection class
IP40.
Replace if damaged.
Gasket for tubular cable housing 3HAC056707-001 Not used with protection class
cover IP40.
Replace if damaged.
Housing cover gasket (IRB 3HAC056698-001 Not used with protection class
1200-7/0.7 ) IP40.
Replace if damaged.
1200-5/0.9 ) IP40.
Replace if damaged.
i For information on which sealing ring to be ordered, see Spare part versions for the axis-1 sealing
ring on IP40/IP67 robots on page 803.

Roundsling, 2 m - Length: 2 m. Lifting capacity: 100 kg.
Guide pin for axis-1 gear unit 3HAC049703-001 Always use three guide pins together!
Calibration toolkit, manual 3HAC051256-001 Includes calibration tools, pins and at-
calibration tachment screws for manual calibration
method. i
i The robot is calibrated by either manual calibration or Axis Calibration at factory. Always use the
same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in the calibration
menu on the FlexPendant.
If no data is found related to standard calibration, manual calibration is used as default.
CAUTION
Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 144.
Cable straps -
Grease 3HAB3537-1 Used for lubrication of cable con-
tact areas.
Grease 3HAC029132-001 Used for lubrication of cable con-
tact areas for robots with food
grade lubrication.

4 Repair
Continued

Locking liquid 3HAB7116-1 Loctite 243
Cleaning agent - Loctite 7063
Flange sealing 12340011-116 Loctite 574
For robots with protection class
Clean Room
Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot. Note
• Reference calibration. External cable
packages (DressPack) and tools can Calibrating axis 6 always requires tools to
stay fitted on the robot. be removed from the mounting flange (also
• Fine calibration. All external cable for reference calibration) since the mount-
packages (DressPack) and tools ing flange is used for installation of the
must be removed from the robot. calibration tool.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 747.
no new reference values can be created,
then reference calibration is not possible.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removing the main cable package

Use these procedures to remove the main cable package from the robot.
Preparations before removing the main cable package

Action Note
1 Decide which calibration routine to use, and take
actions accordingly prior to beginning the repair
procedure.

4 Repair
Continued
Action Note
2 Jog all axes to zero position.
xx1300002581
3
DANGER
Turn off all:

to the robot, before entering the robot working
area.
Getting access to inside of the wrist unit

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
3 Remove the covers on each side of the wrist by For robots with protection class
removing their screws. IP67 (option 287-10)
Note Foundry Plus (option 287-3)
For robots with protection class IP67 (option

287-10)
(option 287-3)
The two front screws on the left hand side cover
(encircled in the figure) have been fitted with
locking liquid.
The tubular cover (left hand side cover) has two
extra screws and washers, as encircled in the
figure.
xx1300002349
Note
Clean Room
figure.
xx1600001148
Disconnecting the axis-5 motor connectors

Action Note
1
DANGER

off.
2 Snap loose the motor connectors from their

holders and then disconnect them.
• R3.MP5
• R3.ME5
Tip
Take photos of the connector and cable position

before disconnecting them, to have as a reference
when reconnecting. xx1300002360
CAUTION

parts on page 144.

4 Repair
Continued
Disconnecting the axis-5 FPC connectors
Action Note
1
DANGER
Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.
2 Snap loose and disconnect the axis-5 FPC

connectors.
CAUTION

xx1300002390
Disconnecting the air hoses

Action Note
1
DANGER

off.
2 Disconnect the air hoses.
CAUTION

parts on page 144.
xx1400000738

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
2
CAUTION

parts on page 144.
3 Remove the cable housing cover.
xx1300002400
4 Remove the plate.
xx1300002413

4 Repair
Continued
Action Note
5 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
6 Remove the small cover of the housing.
xx1300002398

4 Repair
Continued
Action Note
7 Disconnect the remaining FPC connectors.
xx1300002399

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
CAUTION
For robots with safety lamp (option)

Be aware of the signal lamp cables that are at-
tached inside the housing! Disconnect the lamp
cable connectors R3.H1 and R3.H2 and then lift
away the cover completely.
xx1300000456
4 Cut the strap that holds the connectors.
xx1300002494

4 Repair
Continued
Action Note
5 Disconnect the motor connectors.
Tip

when reconnecting.
xx1300002495

Action Note
1
DANGER

off.
2 Pull out the axis-3 motor connectors from the

housing and disconnect them.
CAUTION

parts on page 144.
xx1300002420
Removing the cable package in the housing

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
2 Remove the screw that fastens the air hose hold-
er.
CAUTION

parts on page 144.
xx1300002422
3 Remove the screws that fasten the fix sheet to

the inner plastic guide.
xx1300002421

the motor.
xx1300002423
5 Pull out the fix sheet a bit, to access the screws

that fasten the cable bracket to the sheet.
Loosen the bracket from the sheet by removing
the two screws.
CAUTION
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

4 Repair
Continued
Action Note
6 Valid for IRB 1200-5/0.9
Cut the cable straps at the bottom of the housing.
Disconnecting the cabling in the lower arm

Action Note
1
DANGER

off.
2

3
CAUTION

parts on page 144.
4 Remove the EIB/SMB cover attachment screws

CAUTION

CAUTION

cover! The cover can not be removed completely
until the connectors and lugs are disconnected,
xx1300002427
as shown in following step.

1200 Type A
• R1.ME1-3
• R1.ME4-6
• R2.EIB
Remove the EIB/SMB cover completely from the
lower arm.
1200 Type A
Disconnect the lugs on the EIB/SMB cover.
xx1300002428

4 Repair
Continued
Action Note
xx1700000004

• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
lower arm.
xx1700000005
Removing the cable package in the lower arm

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
3 Pull the cable package out from the upper arm

housing.

4 Repair
Continued
Action Note
4 Remove the fix sheet attachment screws in the
lower arm.
xx1300002426
5 Pull out the cable package a bit from the lower

arm and remove the bracket from the cable
package by removing the screws.
CAUTION

harness.
xx1300002430
6 Cut the cable strap that holds the cabling together

inside the EIB/SMB cavity.
xx1400001130
7 For robots with protection type Clean Room

Remove the swing sealing plug.
Follow the procedure specified in Removing the
swing sealing plug on page 150.
xx1600000205

4 Repair
Continued
Action Note
8 Remove the swing cable housing cover by remov-
ing the screws.
xx1300002431
9 Cut the cable straps.
xx1400001528
10 Remove the axis-2 motor bracket screws.
xx1300002432

4 Repair
Continued
Action Note
11 Pull out the cabling and then remove the axis-2
motor bracket from the cable package by remov-
ing the screws.
CAUTION

harness.
xx1300002433

• R2.ME2
• R2.MP2
xx1300002434
13 Loosen the cable housing from the swing by re-

moving the screws. Leave it hanging on the cable
package.
xx1300002435

4 Repair
Continued
Action Note
14 Remove the axis-2 sealing ring by removing the
screws.
xx1400000020
15 Pull out the cable package from the lower arm.
Tip
There is a groove on the lower arm casting that

simplifies cable passage, if needed. Its position
can easily be felt by hand.
16 Loosen the plastic plate from the cable housing

in order to facilitate continued removal of the cable
package .
xx1400000023
Putting the robot on its side
Action Note
1
DANGER

are turned off.
2
CAUTION

3
CAUTION
The robot weighs .

IRB 1200-5/0.9: 54 kg
IRB 1200-7/0.7: 52 kg
All lifting accessories used must be sized
accordingly!

4 Repair
Continued
Action Note
4 Run a roundsling between the housing and Roundsling, 2 m
the lower arm.
CAUTION
Put the sling on the lower arm side and not

on the cable arm side, which would damage
the robot.
xx1400000679
5
WARNING
The robot is likely to be mechanically un-

stable if not secured to the foundation!
6
CAUTION
The robot weighs .

IRB 1200-5/0.9: 54 kg
IRB 1200-7/0.7: 52 kg
accordingly!

4 Repair
Continued
Action Note
7 Loosen the robot from the foundation by
removing the foundation attachment
screws and put the robot on its side.
xx1400000680
Action Note
1
DANGER

are turned off.
2
CAUTION


4 Repair
Continued
Action Note
3 Remove the bottom cover. Rear connector interface:
xx1300000469
Bottom connector interface:
xx1400000403

4 Repair
Continued
Action Note
4 Remove the axis-1 motor bracket. Rear connector interface:
xx1300000470
xx1400000404
5 Loosen the connectors from the bracket by

cutting the cable straps, and disconnect
the connectors.
xx1300002496

4 Repair
Continued
Separating the arm system from base

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
3 Remove the swing top cover by removing the

screws.
Tip
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.
xx1300000467
xx1300000471

4 Repair
Continued
Action Note
5 Pull out the base slightly and turn it aside.
Tip
Remember the cable layout in the base. The

cabling must be positioned and angled in the
same way during refitting.
xx1300000472
Removing the cable package from the axis-1 sealing ring
Action Note
1
CAUTION

parts on page 144.
2 Remove the axis-1 sealing ring from the swing

and carefully run the cable package out from the
swing.
xx1300002438
3 Remove the swing (including arm system) com-

pletely from the base and lay it aside on a safe
location.
4 Remove the cable bracket from the cabling, if the
cable package is to be replaced with a new spare
part.
xx1300002446

4 Repair
Continued
Removing the cable package from the base

Notice that the procedure differs depending on if the connector interface is located
either at the rear or at the bottom of the base.
Cabling with rear interface

Use this procedure if the cable connector interface is located at the rear of the
base.
Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
3 Open the base cover.
xx1300002448
4 Disconnect the earth cable.

5 Pull the cable package out from the base, through
the rear.
xx1300002456

4 Repair
Continued
Cabling with bottom interface, and cabling routed from below (option 996-1)
Use this procedure if the cable connector interface is located at the bottom of the
base and the cabling is routed from below.
Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
xx1400000405
4 Remove the brake release button from the base

cover.
6 Remove the cable bracket by removing the
screws.
xx1400000406

4 Repair
Continued
Action Note
7 Remove the bracket inside the base by removing
the screws.
xx1400000407

the bottom.
xx1400000411
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
If the cable harness is a new spare part, cut off
100 mm length of each air hose at the upper end.
Note
The same cable harness spare part is used for

IRB 1200-5/0.9 .
Refitting the cable package to the base


base.
Action Note
1 Clean the joints that have been opened. See Cut
parts on page 144

4 Repair
Continued
Action Note
2 For robots with protection class IP67 (option Gasket for rear base cover:
287-10) 3HAC058566-001
(option 287-3)
For robots with with protection type Clean Room
Check the gasket on the base cover.
Replace if damaged.
xx1400000741
3 Insert the cable package in and up through the

base, through the rear.
4 Reconnect the earth cable.
5 Refit the base cover with the attachment screws. Screws: 3HAB3409-212 (M4x16).
Tightening torque: 4 Nm.
xx1300002448
Note

6 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

Note

4 Repair
Continued
Cabling with bottom interface, cabling routed from below (option 996-1)
Action Note
parts on page 144
base, through the bottom.
3 Refit the bracket inside the base with the screws. Tightening torque: 1.5 Nm.
xx1400000407
4 Refit the cable bracket with the screws. Tightening torque: 1.5 Nm.
xx1400000406
287-10) 3HAC058566-001
(option 287-3)
Check the gasket of the base cover.
Replace if damaged.
xx1400000413

7 Refit the brake release button to the base cover.

4 Repair
Continued
Action Note
8 Refit the base cover. Screws: 3HAB3409-212 (M4x16).
xx1400000405
Note


in the figure.
xx1400000480

Note

Refitting the cable package to the axis-1 sealing ring
Action Note
parts on page 144
2 Check the axis-1 sealing ring. Axis-1 sealing ring: 3HAC044676-
Replace if damaged. 001 / 3HAC058568-001 i

4 Repair
Continued
Action Note
3 For robots with protection class IP67 (option Sealant: Sikaflex 521FC.
287-10)
On axis-1 sealing ring version 3HAC056658-001:
Add sealant to the axis-1 sealing ring.
(See Spare part versions for the axis-1 sealing
ring on IP40/IP67 robots on page 803.)
xx1600001125
4 For robots with protection class IP67 (option On axis-1 sealing ring version
287-10) 3HAC044676-001:
On axis-1 sealing ring version 3HAC044676-001 Axis-1 sealing ring gasket:
or 3HAC058568-001: 3HAC045685-001
(option 287-3)
Check the gasket on the axis-1 sealing ring.
Replace if damaged. xx1400000458
On axis-1 sealing ring version

3HAC058568-001:
Axis-1 sealing ring gasket:
3HAC058349-001
xx1600001149
5 For robots with protection class IP67 (option V-ring: 3HAB3732-34

287-10) On axis-1 sealing ring version
On axis-1 sealing ring version 3HAC056658-001 3HAC056658-001:
or 3HAC058568-001:
(option 287-3)
Check the V-ring on the axis-1 sealing ring.
ring on IP40/IP67 robots on page 803.) xx1600001124
Replace if damaged. On axis-1 sealing ring version

3HAC058568-001:
xx1600001150

4 Repair
Continued
Action Note
6 Check the cable protection on the axis-1 sealing Cable protection: 3HAC044691-001
ring. Torx countersunk head screw
Replace if damaged. M3x5: 3HAC14286-4
If replacing the cable protection, use locking liquid Tightening torque: 0.3 Nm
Loctite 243 on the screws.
xx1400000456
7 Refit the cable bracket to the cabling, if removed. Tightening torque: 1 Nm.
Use Loctite 243 on the screw threads.
xx1300002446
8 Refit the axis-1 sealing ring to the swing and Tightening torque: 1.5 Nm.
carefully run the cabling into the swing.
xx1300002438

Note


4 Repair
Continued
Assembling the swing and base
Action Note
1 Clean the joints that have been opened.
before replacing parts on page 144
2 Check the axis-1 radial sealing and the M2 Radial sealing with dust lip: 3HAB3701-47
variseal sealing in the base. M2 variseal sealing: 3HAC044641-002
Replace if damaged.
Note
For Clean Room robots, apply a little

grease to the sealing when replacing the
radial sealing and wipe clean after the re-
placement.
The M2 variseal sealing is only installed on
base version 3HAC049628-001. See Spare
part versions for the base on IP40/IP67 ro-
bots on page 799.
xx1400000472
CAUTION Replacement is detailed in Replacing the

base spare parts (base, axis-1 radial seal-
Do not fit M2 variseal sealing on Clean ing, protection sleeve) on page 447.
Room robots.
3 For robots with protection class IP67 Grease: 3HAC058065-001.

(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
Apply grease to the radial sealing surface.
xx1600000170

4 Repair
Continued
Action Note
4 Fit the guide pins to the drive unit. Guide pin for axis-1 gear unit:
3HAC049703-001
xx1300002566
Always use three guide pins together!

5 Refit the swing to the base with guidance
from the guide pins while running the
cabling up through the swing.
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.
6 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.

4 Repair
Continued
Action Note
7 Remove the guide pins and refit the remain-
ing attachment screws and washers.
xx1300000523
8 Tighten all screws. Tightening torque: 40 Nm.

9 For robots with protection class IP67 Gasket on top swing cover: 3HAC056696-
(option 287-10) 001
Plus (option 287-3)
For robots with with protection type Clean
Room
Check the gasket.
Replace if damaged.
xx1400000425

4 Repair
Continued
Action Note
10 Refit the swing top cover with the screws. Cover on top of swing: 3HAC059679-001
Replace if damaged. : 3HAC056133-001 (used with protection
type Clean Room)
Cover on top of swing, Clean Room
Cover on top of swing, food grade lubrica-
tion
Screws: 3HAB3409-209 (M3x20).
xx1300000467
Note

11 Seal and paint the joints that have been

opened. See Cut the paint or surface on
the robot before replacing parts on page 144
Note
After all repair work, wipe the robot free

from particles with spirit on a lint free cloth.
Connecting the axis-1 motor connectors
Action Note

4 Repair
Continued
Action Note
2 Reconnect the connectors and secure the
connectors to the bracket with cable straps.
xx1300002496
3 Refit the axis-1 motor bracket. Tightening torque: 1.5 Nm.

Rear connector interface:
xx1300000470
xx1400000404

4 Repair
Continued
Action Note
4 For robots with protection class IP67 O-ring: 3HAB3772-86
(option 287-10)
Plus (option 287-3)
Room
Check the O-ring.
Replace if damaged.
xx1400000412
5 Refit the bottom cover. Screws: 3HAB3409-207 (M3x8).

xx1300000469
xx1400000403
Note


4 Repair
Continued
Action Note
Note

Securing the robot to the foundation

Action Note
1
CAUTION
The robot weighs .

IRB 1200-5/0.9: 54 kg
IRB 1200-7/0.7: 52 kg
All lifting accessories used must be
sized accordingly!
2 For robots with: O-ring: 3HAB3772-141

protection class IP67 (option 287-10), For robots with protection class IP67 (option
protection type Foundry Plus (option 287-10)
287-3), Used with protection type Foundry Plus
and manipulator cables routed from For robots with protection type Clean Room
below (option 996-1) For robots with food grade lubrication
Check the gasket at the bottom of the Used with manipulator cables routed from be-
base. low (option 996-1)
Replace if damaged.
xx1500000241
3 Raise the robot to standing and secure Attachment screws: M12x35 (robot installation
to the foundation with the attachment directly on foundation), quality: 8.8.
screws and washers. Washers: 13 x 20 x 2, steel hardness class
300HV.
CAUTION
Pin: 2 pcs, D6x20, ISO 2338 - 6m6x20 - A1.
Always cut the paint with a knife and Tightening Torque: 55 Nm ± 5 Nm.
grind the paint edge when disas-
sembling parts. See Cut the paint or
surface on the robot before replacing
parts on page 144.

4 Repair
Continued
Refitting the cable package in the lower arm

Action Note
parts on page 144
For robots with protection class IP67 (option 001
287-10) Gasket of axis-2 sealing ring:
For robots with protection type Foundry Plus 3HAC045688-001
(option 287-3)
Check the gasket.
Replace if damaged.
xx1400000476
3 For robots with protection class IP67 (option Gasket of plastic plate:
287-10) 3HAC044894-001
(option 287-3)
Check the gasket of the cable housing plastic
plate.
Replace if damaged.
xx1400000457

4 Repair
Continued
Action Note
4 Fetch the cable housing, the plastic plate and the
axis-2 sealing ring and run the cable package
through them.
xx1400000025
5 Fasten the plastic plate to the cable housing, if The plastic plate is included in:
removed. Cable harness material set:
Replace if damaged. 3HAC049663-001.
xx1400000023

4 Repair
Continued
Action Note
6 For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641-
287-10) 004
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
Do not fit M2 variseal sealing on Clean Room ro-

bots.
xx1400000454

4 Repair
Continued
Action Note
7 For robots with protection class IP67 (option Radial sealing with dust lip:
287-10) 3HAB3701-41
(option 287-3)
Check the radial sealing.
Replace if damaged.
Note
For Clean Room robots, apply a little grease to

the sealing when replacing the radial sealing and
wipe clean after the replacement.
xx1400000753
Replacement is detailed in Repla-

cing the swing spare parts (swing,
axis-2 radial sealing) on page 522.
8 Guide the cable package into the lower arm.
Tip

9 Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm.
xx1400000020

4 Repair
Continued
Action Note
10 Refit the cable housing with the screws. Screws: 3HAB3409-236 (M4x10).
xx1300002435
Note

11 Apply grease to the cable package, cover all

xx1400000481

4 Repair
Continued
Action Note
12 Reconnect the motor connectors.
• R2.ME2
• R2.MP2
xx1300002434
13 Refit the axis-2 motor bracket to the cable pack- Tightening torque: 1.5 Nm.
age with the two screws.
CAUTION

harness.
xx1400000021
14 Refit the axis-2 motor bracket to the motor.
xx1300002432

4 Repair
Continued
Action Note
15 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

xx1400000482
17 In order to keep the cabling away from the hot

axis-2 motor, the cable package must be secured
accordingly inside the EIB/SMB cavity:
1 The cable package is strapped with tape
by the supplier at two locations. Put a cable
strap around the cable package at each
location.
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

4 Repair
Continued
Action Note
18 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056726-001
(option 287-3)
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000424
19 Check the PTFE film. PTFE film on cable housing cover:

Replace if damaged. 3HAC044660-001
20 Apply grease to the inner surface of the cable

housing cover and to the PTFE film surface.

4 Repair
Continued
Action Note
21 Refit the cable housing cover. Cable housing cover of the swing:
: 3HAC056214-001 (used with pro-
Note tection type Clean Room)
Cable housing cover of the swing,
Remember to refit the two lower screws shown Clean Room
in the figure. Cable housing cover of the swing,
food grade lubrication
Screws: 3HAB3409-207 (M3x8).
xx1300002431
Note

(option 287-3) 3HAC4836-24
Check the protection plugs for lifting holes.
Replace if damaged.
xx1600001151

4 Repair
Continued
Action Note
23 For robots with with protection type Clean Room Swing sealing plug:3HAC053687-
Refit the swing sealing plug.
Follow the procedure specified in Refitting the
xx1600000205
24 Refit the lower arm bracket to the cable package. Tightening torque: 1.5 Nm.
CAUTION

harness.
xx1300002430

Note

Connecting the cabling in the lower arm

Action Note
1


parts on page 144

4 Repair
Continued
Action Note
3 For robots with protection class IP67 (option Gasket on EIB/SMB cover:
287-10) 3HAC056728-001
(option 287-3)
Check the EIB/SMB cover gasket.
Replace if damaged.
xx1400000475

1200 Type A
• R1.ME1-3
• R1.ME4-6
• R2.EIB
WARNING

5 Valid for IRB 1200 (no type specified) and IRB xx1300002428
1200 Type A
Connect the lugs to the EIB/SMB cover.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING

xx1700000005

4 Repair
Continued
Action Note
xx1700000004
xx1300002427
Note


4 Repair
Continued
Action Note
9 Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm.
arm.
xx1300002426

Note

Refitting the cable package in the housing

Action Note
parts on page 144
2 Before guiding the cable package into the housing Area to be lubricated, shown in
and upper arm, apply grease to the cable package, cable package already fitted to the
to the area going into the upper arm, shown in the housing.
figure. Cover all moving area of the package.
xx1400000483

4 Repair
Continued
Action Note
3 Guide the cable package into the upper arm,
through the housing.
Note
Guide the air hoses (A) underneath the bottom

side of the axis-3 motor and the axis-3 motor
cables (B) on top of the motor, see cable layout
figure. The fix point of the air hoses is pre-determ-
ined (marked) and must be matched against the
air hose holder on the left side of the axis-3 motor.
xx1400001472
Note
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.
4 Refit the bracket to the sheet with two screws. Tightening torque: 1.5 Nm.
CAUTION

harness.
xx1300002424
5 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm.
xx1300002423

4 Repair
Continued
Action Note
6 Refit the fix sheet to the inner plastic guide. Tightening torque: 1.5 Nm.
xx1300002421
7 Fit the air hose holder to the bracket. Air hose holders are included in
Replace the holder, if damaged. Cable harness material set
(3HAC049663-001).
Tip
If the air hose holder is difficult to fit, firstly remove

the bracket from the fix sheet by removing the two
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
8 Reconnect the axis-3 motor connectors.
xx1300002420

4 Repair
Continued
Action Note
xx1400000754

Secure the cable package at the bottom of the
housing with cable straps.
Note


Action Note
CAUTION

parts on page 144.
xx1300002371

4 Repair
Continued
Action Note
2 Secure the connectors to the motor with a cable
strap.
xx1300002494
Connecting the axis-4 FPC connectors

Action Note
parts on page 144
2 Reconnect the FPC connectors.
Tip
See the number markings on the connectors for

help to find the corresponding connector.
xx1300002399

4 Repair
Continued
Action Note
3 Reconnect the FPC connectors and push them Cable layout in IRB 1200-7/0.7 :
into place inside the housing.
Tip

xx1300002412
xx1400001471
4 Remove residual locking liquid and other pollut-

ants with cleaning agent Loctite 7063.

4 Repair
Continued
Action Note
287-10)
(option 287-3)
Apply flange sealing Sikaflex 521FC on the
mounting surfaces of the small cover on the
housing.
6 Refit the small cover to the housing.
Replace if damaged.
xx1300002398
Housing small cover: 3HAC059684-

001
tection type Clean Room)
Housing small cover, Clean Room
Housing small cover, food grade
lubrication
Screws: 3HAC14286-4 (M3X5).
Apply a string of the sealant Sikaflex 521FC to
the joint of the small cover on the housing.
Smooth out the sealant string using a finger tip.
joint.
If necessary, add extra sealant to get a full cover
joint.
xx1600000214

4 Repair
Continued
Action Note
8 Refit the plate. Tightening torque: 1.5 Nm.
xx1300002413
9 Check the PTFE film on the cable housing. PTFE film on lower arm cable
Replace if damaged. housing: 3HAC044710-001
xx1400000740

4 Repair
Continued
Action Note
287-10) 3HAC056724-001
For robots with protection type Foundry Plus PTFE film on cable housing cover:
(option 287-3) 3HAC044660-001
Replace if damaged.
xx1400000048
11 Check the PTFE film on the cable housing cover.

Replace if damaged.
housing cover and the PTFE film surface.

4 Repair
Continued
Action Note
13 Refit the cable housing cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm
xx1300002400
Note


Note

Connecting the air hoses and CP/CS cabling (if equipped)

Action Note
1 Reconnect the air hoses. Air connector set with Ethernet
hole in flange: 3HAC049664-001
CAUTION Air connector set without Ethernet
parts on page 144.
xx1400000738

4 Repair
Continued
Action Note
2 If equipped, reconnect the CP/CS connector.
287-10)
(option 287-3)
1 Check the gasket.
2 Replace if damaged.
For robots with protection type Clean Room: xx1500000252
1 Remove residual locking liquid and other
pollutants with cleaning agent Loctite 7063. On robots with protection class
2 Apply flange sealing Loctite 574 on the IP67
mounting surfaces of the CP/CS connector On robots with protection type
and wipe clean if there is any overflowing Foundry Plus
Loctite 574. Gasket: 3HAC058567-001
xx1500000251
3 For robots with protection type Foundry Plus Protection bracket for CP/CS con-
If required, fit the protection bracket for CP/CS nectors: 3HAC058350-001
connectors.
xx1600001152
Connecting the axis-5 motor FPC connectors
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION

xx1300002390

4 Repair
Continued

Action Note
1 Reconnect the motor cables.
• R3.MP5
• R3.ME5
CAUTION

parts on page 144.
xx1300002360
Refitting the wrist covers
Action Note
2 For robots with protection class IP67 Gasket for tubular cover: 3HAC058822-001
(option 287-10)
Plus (option 287-3)
Room
Check the tubular cover gasket.
Replace if damaged.
xx1400000034
3 For robots with protection class IP67 Gasket for tubular cable housing cover:
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
4 Refit the both covers to the wrist. Screws: 3HAB3409-207 (M3x8).
For robots with protection class IP67 Tightening torque: 1.5 Nm.
(option 287-10) For robots with protection class IP67 (op-
For robots with protection type Foundry tion 287-10)
Plus (option 287-3) For robots with protection type Foundry
Apply locking liquid Loctite 243 to the two Plus (option 287-3)
front screws on the left hand side cover,
encircled in the figure.
Remember to refit the extra two screws and
washers to the tubular cover.
Room
xx1300002349
xx1600001153
Note


Note


4 Repair
Continued
Action Note
1 For robots with protection class IP67 Housing cover gasket (IRB 1200-7/0.7 ):
(option 287-10) 3HAC056698-001
For robots with protection type Foundry Housing cover gasket (IRB 1200-5/0.9 ):
Plus (option 287-3) 3HAC056697-001
Room
Check the gasket.
Replace if damaged.
xx1400000477
2 Refit the upper arm housing cover with the Screws: 3HAB3409-207 (M3x8).
screws. Tightening torque: 1.5 Nm.
CAUTION

Reconnect the lamp cable connectors
R3.H1 and R3.H2 and then secure the
cover.
xx1300000456
Note

3 For robots with protection type Clean

Room
Apply a string of the sealant Sikaflex 521FC
to the joint of the upper arm housing cover.
Smooth out the sealant string using a finger
tip. Use washing-up on finger tips to get a
smooth joint.
If necessary, add extra sealant to get a full
cover joint.
xx1600000215

4 Repair
Continued
Action Note
Room:
Clean and paint the joints that have been
Note

free cloth.
5 Recalibrate the robot. Calibration is detailed in section Calibration

on page 737.
6
DANGER

page 28.

4 Repair
4.3.2 Replacing the axis-4 FPC unit, housing extender unit and housing extender
sealings
Location of the FPC unit

The axis-4 FPC unit and the housing extender sealings are located inside the
housing extender unit, as shown in the figure.
xx1300002419
Note

FPC unit, axis 4 3HAC055517-001
IP40.
Replace if damaged.
Foundry Plus.
Replace if damaged.
Housing extender unit 3HAC059686-001 Replace if damaged.

4 Repair
Continued

Housing extender unit, Clean 3HAC059703-001 Used with protection type Clean
Room Room.
Housing extender unit, food Used for robots with food grade
Replace if damaged.
IP40.
Replace if damaged.
cover
Washer 3HAC044869-001 Replace if damaged
Room Room.
Replace if damaged.
IP40.
Replace if damaged.
cover IP40.
Replace if damaged.

Axis-4 sealing assembly tool 3HAC049699-001 Used to refit the radial sealing, if re-
set placement is needed.

Clean Room

4 Repair
Continued

Action Note
calibration:
Removing the FPC unit and the housing extender sealings

Use these procedures to remove the axis-4 FPC unit and the housing extender
sealings.
Preparations before removing the axis-4 FPC unit

Action Note
procedure.
2 Jog axis 4 to zero position.
3
DANGER
Turn off all:

area.

4 Repair
Continued

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

287-10)
(option 287-3)
locking liquid.
figure.
xx1300002349
Note
Clean Room
figure.
xx1600001148

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
• R3.MP5
• R3.ME5
Tip

CAUTION

parts on page 144.
Removing the axis-5 motor with pulley
Action Note
1
DANGER

are turned off.
2
CAUTION

3 Loosen the screws so that the motor can

be moved sideways.
xx1300002350

4 Repair
Continued
Action Note
4 Remove the timing belt.
xx1300002351

connectors.
xx1300002390
6 Remove the screws and pull out the motor.
xx1300002352
Removing the wrist

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
3 Disconnect the connectors shown in the figure.
xx1300002353
xx1300002355
5 Remove the connector plate attachment screws.
xx1300002356
6 Guide the hoses through the plate hole and re-

move the plate.
xx1300002357

4 Repair
Continued
Action Note
7 Support the weight of the wrist and remove the
screws and the washer.
xx1300002358
8 Pull out the wrist carefully while at the same time

pulling all connectors and the air hoses out of the
wrist.
Be careful not to damage the FPC cabling and the
connectors.
CAUTION xx1300002359
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

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
xx1300002400
4 Remove the plate.
xx1300002413

4 Repair
Continued
Action Note
disconnect them.
xx1300002412
xx1400001471
xx1300002398

4 Repair
Continued
Action Note
xx1300002399
Removing the housing extender unit

Action Note
1
CAUTION

parts on page 144.
2 Remove the axis-4 FPC unit screws.
xx1300002373

Remove the plugs covering the extender unit
screws with a needle-nose plier.
xx1600000262
4 Remove the extender unit screws.
xx1300002372

4 Repair
Continued
Action Note
5 Remove the housing extender unit.
Be careful not to damage the cabling.
xx1300002374
Removing the axis-4 mechanical stop

Action Note
1
CAUTION

parts on page 144.
2 Remove the mechanical stop assembly from the

housing extender unit by removing the screws.
xx1300002415
Removing the axis-4 FPC unit
Action Note
1
CAUTION


4 Repair
Continued
Action Note
2 Remove the FPC unit from the housing
extender unit by removing the screws.
CAUTION
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
Refitting the FPC unit and the housing extender sealings

Use these procedures to refit the FPC unit and the housing extender sealings.
Checking the housing extender sealings
Action Note
2 For robots with protection class IP67 M2 variseal sealing: 3HAC044641-007
(option 287-10)
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
Do not fit M2 variseal sealing on Clean

Room robots.
xx1300002418

4 Repair
Continued
Action Note
3 For robots with protection class IP67 Radial sealing with dust lip: 3HAB3701-48
(option 287-10)
Plus (option 287-3)
Room
Replace if damaged, as described below.
In order to replace the radial sealing, both
the axis-4 mechanical stop and the axis-4
FPC unit must be removed from the hous-
ing extender unit, if not already removed.
xx1400000438
4 Apply a little grease to the sealing when

replacing the radial sealing and wipe clean
after the replacement.
5 Fit the radial sealing into the housing ex-
tender unit.
6 Fit the circular part of the radial sealing Axis-4 sealing assembly tool set:
assembly tool against the radial sealing. 3HAC049699-001
7 Fit the tool plate to the other side of the
housing extender unit with the six screws
M6X50.
xx1400000436

4 Repair
Continued
Action Note
8 Screw the screws, little by little, to press
the sealing into place.
xx1400000437
9 Remove the assembly tool.

10 Check that the sealing is undamaged and
properly fitted.
11 Refit both the axis-4 mechanical stop and
the axis-4 FPC unit to the housing extender
unit.
Note

Refitting the axis-4 FPC unit
Action Note

4 Repair
Continued
Action Note
2 Refit the FPC unit to the housing extender Tightening torque: 0.5 Nm.
unit and secure with the screws.
CAUTION
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.
CAUTION
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. xx1300002417
xx1300002611

Note

Refitting the housing extender unit

Action Note
parts on page 144
287-10)
(option 287-3)
Remove residual locking liquid and other pollut-
Apply flange sealing Loctite 574 on the mounting
surfaces of the housing extender unit.
Note
For Clean Room robots, wipe clean the overflow-

ing Loctite 574 if there is any.
xx1300002613

4 Repair
Continued
Action Note
Make sure the four cavities are fully filled with
glue. If not, fill glue again before the refitting.
xx1600000216
4 Refit the housing extender unit to the housing

while putting the FPC cables into the housing and
the air hoses through the housing extender unit.
CAUTION
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.
5 Secure with screws and washers, using locking Screws: M4x30.

liquid Loctite 243. Tightening torque: 2.7 Nm.
xx1300002372
6 For robots with protection type Foundry Plus Screw sealing plug: 3HAC053685-
(option 287-3) 001
Press in screw sealing plugs to cover the screws.
xx1600000263

4 Repair
Continued
Action Note
7 Fit and secure the axis-4 FPC unit screws. Tightening torque: 0.3 Nm.
xx1300002373

Note


Action Note
parts on page 144
Tip

xx1300002399

4 Repair
Continued
Action Note
Tip

xx1300002412
xx1400001471


4 Repair
Continued
Action Note
287-10)
(option 287-3)
housing.
Replace if damaged.
xx1300002398

001
lubrication
joint.
joint.
xx1600000214

4 Repair
Continued
Action Note
xx1300002413
xx1400000740

4 Repair
Continued
Action Note
287-10) 3HAC056724-001
(option 287-3) 3HAC044660-001
Replace if damaged.
xx1400000048

Replace if damaged.

4 Repair
Continued
Action Note
xx1300002400
Note


Note

Refitting the wrist

Action Note
parts on page 144

4 Repair
Continued
Action Note
2 Put the connectors and air hoses into the wrist
carefully while at the same time refitting the wrist
to the housing extender unit.
connectors.

xx1300002611
3 Refit the washer while at the same time putting Washer: 3HAC044869-001
the cables through its center.
Replace washer, if damaged.
xx1400000001

4 Repair
Continued
Action Note
4 Refit the screw M6x35 (1 pc). Do not tighten yet. Screw: 3HAB3409-238 (M6x35 (1
pc)).
xx1400000002
Note

5 Refit the rest of the screws (M5x35 (7 pcs)). Screw: 3HAB3409-237 (M5x35 (7
pcs)).
xx1400000003
Note


7 Put the cables through the plate hole and refit the Tightening torque: 0.3 Nm.
plate.
xx1300002356

4 Repair
Continued
Action Note
8 Reconnect the air hoses.
CAUTION
Make sure to connect the air hoses correctly, ac-

cording to the marking on hoses and connectors.
xx1300002355
9 Reconnect the connectors.

• R3.Eth
• R3.CPCS
xx1300002353

Note

Preparations before securing the axis-5 motor

Action Note
1 Check that:
• all assembly surfaces are clean and without
damages
• the motor is clean and undamaged.
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
2 Place the motor at its mounting position and Screws: 3HAB3409-212 (M4x16).
fasten the attachment screws and washers just
enough to still be able to move the motor.
xx1300002463
Note

Securing the axis-5 motor and timing belt
Action Note
2 Refit the timing belt on the pulley.
xx1300002351
3 Move the motor to a position where a good

timing belt tension is reached (F = 26 N). Note
Do not strech the timing belt too much!
4 Secure the motor with its attachment

screws.
xx1300002350

4 Repair
Continued
Action Note
Note

Action Note
CAUTION

xx1300002390

Action Note
• R3.MP5
• R3.ME5
CAUTION

parts on page 144.
xx1300002360
Action Note

4 Repair
Continued
Action Note
(option 287-10)
Plus (option 287-3)
Room
Replace if damaged.
xx1400000034
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
Room
xx1300002349
xx1600001153
Note


Note


4 Repair
Continued
Action Note
1
CAUTION

Note

free cloth.
2 Recalibrate the robot. Calibration information is included in sec-

tion Calibration on page 737.
3
DANGER

page 28.

4 Repair
4.3.3 Replacing the axis-5 FPC unit
Location of axis-5 FPC unit

The axis-5 FPC unit is located as shown in the figure.
xx1300002397
Note

FPC unit, axis 5 3HAC045743-001
M2 variseal sealing 3HAC044641-009 Replace if damaged.
Radial sealing 3HAB3701-42 Not used with protection class
IP40.
Replace if damaged.
Gasket for tubular cable 3HAC056707-001 Not used with protection class
housing cover IP40.
Replace if damaged.


4 Repair
Continued


Removing the FPC unit

Use these procedures to remove the FPC unit.
Preparations before removing the axis-5 FPC unit

Action Note
xx1300002581
2
DANGER
Turn off all:

area.
3
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
4 Remove the tubular cable housing cover.
xx1300002389
Removing the tubular cable housing

Action Note
1
CAUTION

parts on page 144.
2 Snap loose and disconnect the axis-5 FPC con-

nectors.
xx1300002390
3 Remove the connector plate by first removing the

screws.
xx1300002391
4 Remove the cable housing of the tubular by first

Note

287-10)
(option 287-3)
The frame is glued and needs to be pried off.
xx1300002392

4 Repair
Continued

Action Note
1
CAUTION

parts on page 144.
2 Remove the sleeve screws.
xx1300002393
3 Remove the sleeve by screwing in two of the

screws into the press out holes to force the sleeve
out.
xx1300002582
4 Remove the FPC unit attachment screws and pull

out the FPC unit as far as required for the axis-6
motor connectors to be accessed.
xx1300002394

4 Repair
Continued
Action Note
5 Disconnect the axis-6 motor connectors and re-
move the FPC unit completely.
xx1300002395
Refitting the FPC unit

Use these procedures to refit the FPC unit.
Action Note
1
WARNING
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.

3 Reconnect the axis-6 motor connectors to
the FPC unit.
xx1300002395

4 Repair
Continued
Action Note
4 Carefully refit the FPC unit and secure with Tightening torque: 0.3 Nm.
screws.
Note
Check that the FPC unit is at the zero pos-

ition when refitting it.
xx1300002394
5 For robots with protection class IP67

(option 287-10)
Plus (option 287-3)
Remove residual locking liquid and other
pollutants with cleaning agent Loctite 7063.
Apply flange sealing Loctite 574 on the
mounting surfaces of the sleeve.
Note
For Clean Room robots, wipe clean the

overflowing Loctite 574 if there is any.
xx1300002609
6 Refit the sleeve and secure with screws. Sleeve: 3HAC044661-001

Replace if damaged. Tightening torque: 1.5 Nm.
xx1300002393

4 Repair
Continued
Action Note
Note

Checking the tubular cable housing sealings
Action Note
2 Check the sealing. M2 variseal sealing: 3HAC044641-009
Replace if damaged.
CAUTION

Room robots.
xx1300002396
3 For robots with protection class IP67 Radial sealing: 3HAB3701-42

(option 287-10)
Plus (option 287-3)
Room
If undamaged and properly seated, skip to
the next procedure table.
xx1300002608

5 Fit the radial sealing into the tubular cable
housing.

4 Repair
Continued
Action Note
tubular cable housing with the six screws
M6x40.
xx1400000485

xx1400000486

properly fitted.
Note


4 Repair
Continued
Refitting the tubular cable housing

Action Note
parts on page 144
287-10)
(option 287-3)
surfaces of the tubular cable housing.
xx1300002610
Note

3 Refit the tubular cable housing with the screws. Tightening torque: 1.5 Nm.
Tubular cable housing:
3HAC059695-001
Tubular cable housing, Clean
Room
Tubular cable housing, food grade
lubrication
xx1300002392

Note

Refitting the connector plate
Action Note

4 Repair
Continued
Action Note
2 Refit the connector plate and secure with Tightening torque: 0.3 Nm.
the M3 screws.
xx1400001401
3 Secure the three M2.5 screws. Tightening torque: 0.3 Nm.
xx1400001402

Note

Action Note
CAUTION

xx1300002390

4 Repair
Continued
Refitting the tubular cable housing cover
Action Note
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345
3 Refit the cover to the cable housing. Screws: 3HAB3409-207 (M3x8).

xx1300002389
Note


Note


4 Repair
Continued
Action Note
1
CAUTION

Note

free cloth.
2
DANGER

page 28.

4 Repair
4.3.4 Replacing the EIB/SMB unit
Location of EIB/SMB unit

The EIB/SMB unit is located as shown in the figure.
Note
The EIB unit is used for IRB 1200 no type specified and IRB 1200 Type A.
The SMB unit is used for IRB 1200 Type B.
xx1300002574

4 Repair
Continued
Note

EIB unit 3HAC045759-001
SMB unit 3HAC059122-001 Used for IRB 1200 Type B. See
Type B of IRB 1200 on page 798.
IP40.
Replace if damaged.
IP40.
Replace if damaged.

Removing the EIB/SMB unit

Use these procedures to remove the EIB/SMB unit.
Preparations before removing the EIB/SMB unit
Action Note
1
DANGER
Turn off all:

working area.
2
CAUTION


4 Repair
Continued
Action Note
3 Remove the lower arm cable housing cov-
er.
xx1300002400

Action Note
1
DANGER

off.
2

3
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
CAUTION

CAUTION

xx1300002427

1200 Type A
• R1.ME1-3
• R1.ME4-6
• R2.EIB
lower arm.
1200 Type A
xx1300002428

xx1700000004

4 Repair
Continued
Action Note
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
lower arm.
xx1700000005
Removing the EIB unit (IRB 1200 no type specified and IRB 1200 Type A)
Action Note
1

2
CAUTION

parts on page 144.
3 Disconnect the battery cable.
xx1300002571

4 Repair
Continued
Action Note
4 Remove the battery pack plate by removing the
screws.
xx1300002572
5 Remove the EIB unit by removing the distance

screws.
xx1300002573
Removing the SMB unit (IRB 1200 Type B)

Action Note
1

2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
3 Disconnect the battery cable.
xx1700000006
4 Remove the battery pack plate by removing the

screws.
xx1700000008
5 Remove the SMB unit by removing the distance

screws.
xx1700000009

4 Repair
Continued
Refitting the EIB/SMB unit

Use these procedures to refit the EIB/SMB unit.
Refitting the EIB unit (IRB 1200 no type specified and IRB 1200 Type A)
Action Note
1


parts on page 144
3 Refit the EIB unit with the distance screws.
xx1300002573
4 Refit the battery pack plate with the screws. Tightening torque: 1.5 Nm.
xx1300002572

4 Repair
Continued
Action Note
5 Reconnect the battery cable.
xx1300002571

Note

Refitting the SMB unit (IRB 1200 Type B)

Action Note
1


parts on page 144

4 Repair
Continued
Action Note
3 Refit the SMB unit with the distance screws.
xx1700000009
4 Refit the battery pack plate with the screws. Tightening torque: 1.5 Nm.
xx1700000008
5 Reconnect the battery cable.
xx1700000006

4 Repair
Continued
Action Note
Note


Action Note
1


parts on page 144
287-10) 3HAC056728-001
(option 287-3)
Replace if damaged.
xx1400000475

4 Repair
Continued
Action Note
1200 Type A
• R1.ME1-3
• R1.ME4-6
• R2.EIB
WARNING

1200 Type A
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING

xx1700000005

xx1700000004

4 Repair
Continued
Action Note
xx1300002427
Note

arm.
xx1300002426

Note


4 Repair
Continued
Action Note
1 For robots with protection class IP67 Gasket on cable housing cover:
(option 287-10) 3HAC056724-001
Plus (option 287-3)
Room
Check the gasket of the cable housing
cover.
Replace if damaged.
xx1400000048
2 Check the PTFE film on the cable housing PTFE film on cable housing cover:
cover. 3HAC044660-001
Replace if damaged.
3 Apply grease to the inner surface of the
cable housing cover and the PTFE film
surface.

4 Repair
Continued
Action Note
xx1300002400
Note

5 Update the revolution counters. See Updating revolution counters on

page 743.
6
CAUTION

Note

free cloth.
7
DANGER

page 28.

4 Repair
4.4.1 Replacing the lower arm
4.4 Upper and lower arms
Location of the lower arm

The lower arm is located as shown in the figure.
xx1400000423
Note

Lower arm (IRB 1200-7/0.7 ) 3HAC059687-001 Includes guide pin.
Lower arm, Clean Room (IRB 3HAC059704-001 Used with protection type Clean
1200-7/0.7 ) Room.
Lower arm, food grade lubrica- Used for robots with food grade
tion (IRB 1200-7/0.7 ) lubrication.
Includes guide pin.

4 Repair
Continued

Lower arm (IRB 1200-5/0.9 ) 3HAC059688-001 Includes guide pin.
Lower arm, Clean Room (IRB 3HAC059705-001 Used with protection type Clean
1200-5/0.9 ) Room.
Lower arm, food grade lubrica- Used for robots with food grade
tion (IRB 1200-5/0.9 ) lubrication.
Includes guide pin.
Foundry Plus.
Replace if damaged.
Cable housing of the lower arm 3HAC059690-001 Replace if damaged.
Cable housing of the lower arm, 3HAC056135-001 Used with protection type Clean
Clean Room Room.
Cable housing of the lower arm, Used for robots with food grade
food grade lubrication lubrication.
Replace if damaged.
Gasket on lower arm cable 3HAC044895-001 Not used with protection class
housing IP40.
Replace if damaged.
Foundry Plus.
Replace if damaged.
Radial sealing 3HAC024865-001 Not used with protection class
IP40.
Replace if damaged.
Gasket of axis-2 sealing ring 3HAC045688-001 Not used with protection class
IP40.
Replace if damaged.
Gasket of plastic plate 3HAC044894-001 Not used with protection class
IP40.
Replace if damaged.
Lower arm cover 3HAC059689-001 Replace if damaged.
Lower arm cover, Clean Room 3HAC056136-001 Used with protection type Clean
Lower arm cover, food grade Room.
lubrication Used for robots with food grade
lubrication.
Replace if damaged.
Gasket on lower arm cover 3HAC056725-001 Not used with protection class
IP40.
Replace if damaged.
Cable housing of the swing 3HAC059677-001 Replace if damaged.
Cable housing of the swing, 3HAC056213-001 Used with protection type Clean
Clean Room Room.
Cable housing of the swing, food Used for robots with food grade
Replace if damaged.

4 Repair
Continued

swing
Replace if damaged.
tion class IP40.
Replace if damaged.
Foundry Plus.
Replace if damaged.
Foundry Plus.
Replace if damaged.
IP40.
Replace if damaged.
O-ring 3HAC048939-001 Replace if damaged.
Swing cover 3HAC059676-001 Replace if damaged.
Swing cover, Clean Room 3HAC056215-001 Used with protection type Clean
Swing cover, food grade lubrica- Room.
tion Used for robots with food grade
lubrication.
Replace if damaged.
Gasket on swing cover 3HAC056727-001 Not used with protection class
IP40.
Replace if damaged.
tion in tubular.
Room Room.
Replace if damaged.
IP40.
Replace if damaged.
cover
IP40.
Replace if damaged.

4 Repair
Continued

cover IP40.
Replace if damaged.
1200-7/0.7 ) IP40.
Replace if damaged.
1200-5/0.9 ) IP40.
Replace if damaged.
Cable straps -
tact areas.
grade lubrication.
Clean Room

Guide pin for upper arm 3HAC049705-001 Always use three guide pins together!
method. i

4 Repair
Continued

Action Note
calibration:
Removing the lower arm

Use this procedure to remove the lower arm.
Preparations before removing the lower arm
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
xx1300002581

4 Repair
Continued
Action Note
3
DANGER
Turn off all:

working area.

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

287-10)
(option 287-3)
locking liquid.
figure.
xx1300002349
Note
Clean Room
figure.
xx1600001148

4 Repair
Continued

Action Note
1
DANGER

off.

• R3.MP5
• R3.ME5
Tip

CAUTION

parts on page 144.
Action Note
1
DANGER

are turned off.

connectors.
CAUTION

xx1300002390

4 Repair
Continued

Action Note
1
DANGER

off.
CAUTION

parts on page 144.
xx1400000738

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
xx1300002400

4 Repair
Continued
Action Note
4 Remove the plate.
xx1300002413
disconnect them.
xx1300002412
xx1400001471

4 Repair
Continued
Action Note
xx1300002398
xx1300002399

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
CAUTION

xx1300000456
xx1300002494
Tip

when reconnecting.
xx1300002495

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
CAUTION

parts on page 144.
xx1300002420

Action Note
1
DANGER

off.

er.
CAUTION

parts on page 144.
xx1300002422

xx1300002421

4 Repair
Continued
Action Note
the motor.
xx1300002423

the two screws.
CAUTION

harness.
xx1300002424


Action Note
1
DANGER

off.
2

3
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
CAUTION

CAUTION

xx1300002427

1200 Type A
• R1.ME1-3
• R1.ME4-6
• R2.EIB
lower arm.
1200 Type A
xx1300002428

xx1700000004

4 Repair
Continued
Action Note
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
lower arm.
xx1700000005

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

housing.
lower arm.
xx1300002426

4 Repair
Continued
Action Note
CAUTION

harness.
xx1300002430

xx1400001130

xx1600000205

ing the screws.
xx1300002431

4 Repair
Continued
Action Note
xx1400001528
xx1300002432

ing the screws.
CAUTION

harness.
xx1300002433

4 Repair
Continued
Action Note
• R2.ME2
• R2.MP2
xx1300002434

package.
xx1300002435

screws.
xx1400000020
Tip


4 Repair
Continued
Action Note
package .
xx1400000023
Removing the lower arm cable housing
Action Note
1
DANGER

are turned off.
2
CAUTION

3 Remove the cable housing of the lower arm

by removing the screws.
xx1300002529

4 Repair
Continued
Removing the upper arm
Action Note
1
DANGER

are turned off.
2
CAUTION

3 Remove the lower arm cover.
xx1300002528
4
CAUTION
The upper arm weighs 17 kg.

accordingly!
5 Fit lifting slings to the upper arm to support

the weight of the arm. (no force)

4 Repair
Continued
Action Note
6 Remove the upper arm screws.
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
7 Fit guide pins to the upper arm. Guide pin for upper arm: 3HAC049705-001
xx1400000771
8 Separate the upper and lower arm with

guidance from the guide pins.
xx1300002533

4 Repair
Continued
Action Note
1
DANGER

are turned off.
2
CAUTION

3 Remove the swing cover.
xx1300002551
4 Remove the lower arm screws and wash-

ers.
WARNING
This releases the lower arm from the swing.

Make sure the weight of the arm is properly
secured.
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

4 Repair
Continued
Action Note
5 Fit guide pins to the gearbox. Guide pin for axis-2 gear unit:
3HAC049704-001
xx1300002563
6 Separate the lower arm from the swing.
Tip
If the lower arm is hard to loosen from the

swing, two of the lower arm screws can be
refitted in their attachment holes. 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
Removing the axis-2 drive unit
Action Note
1
DANGER

are turned off.
2
CAUTION


4 Repair
Continued
Action Note
3
CAUTION
The lower and upper arms together weigh

30 kg.
accordingly!
4 If there is enough space on the site, lay

down the lower arm on a workbench. Make
sure to support the gravity center of the
lower arm.
If the site is cramp, the procedure can be
performed having the lower arm hanging
in the lifting slings.
If removing the axis-2 drive unit from a
hanging lower arm, it is best performed by
two persons working together:
• Person 1: Hold the lower arm still.
• Person 2: Remove the drive unit
screws according to step below.
xx1300002554
5 Remove the grey screws from the drive
unit.
WARNING
Keep the eight black screws fitted. They

hold the gearbox together. Removing them
can damage the gearbox severely.
6 Insert two M4 screws to the press out holes

and press out the drive unit.
xx1400000008
7 Carefully pull out the complete drive unit.
xx1300002555

4 Repair
Continued
Refitting the lower arm

Use these procedures to refit the lower arm.
Refitting the axis-2 drive unit
Action Note
2 Check if there is a sufficient amount of Harmonic grease 4B No. 2: 3HAC037302-
grease on the gear. Apply more grease, if 001.
needed. LUBRIPLATE SYNXTREME FG-0:
3HAC043771-001 (for robots with food
grade lubrication).
(option 287-10)
Plus (option 287-3)
mounting surfaces of the lower arm.
Note

xx1400000006

4 Repair
Continued
Action Note
4 Carefully insert the complete drive unit.
Note
Pay attention to the relative position

between the motor connector block and
the lower arm, so that the drive unit is posi-
tioned correctly inside the lower arm.
xx1300002580
xx1400000795
The figure shows the position of the motor

connector block when axis 2 is in position
0°.
5 If the gear is refitted in a hanging lower Screws: 3HAB3409-239 ( M4x35).

arm, this step requires two persons.
• Person 2: Refit the drive unit screws.
Secure the screws but do not tighten yet.
xx1300002554
Note

6 If the drive unit is refitted in a hanging lower Tightening torque: 5 Nm

• Person 2: Tighten the screws.

4 Repair
Continued
Action Note
Note

Action Note
2 Check the o-ring. O-ring: 3HAC048939-001
Replace if damaged.
xx1300002556

Apply flange sealing Loctite 574 to the cyl-
indrical surface in the swing.
Note

xx1400001403

4 Repair
Continued
Action Note
3HAC049704-001
xx1300002562

(option 287-10)
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

Room robots.
xx1400000453
6 Fit the lower arm to the swing, with guid-

ance from the guide pins.
xx1300002563

4 Repair
Continued
Action Note
7 Refit the lower arm screws and washers, Screws: 3HAB3409-51 (M10x30).
using locking liquid Loctite 243.
xx1300002564
Note


ing screws and washers using locking li-
quid Loctite 243.
xx1300002565
9 Tighten all screws. Tightening torque: 45 Nm

4 Repair
Continued
Action Note
10 For robots with protection class IP67 Gasket on swing cover: 3HAC056727-001
(option 287-10)
Plus (option 287-3)
Room
Check the swing cover gasket.
Replace if damaged.
xx1400000007
11 Refit the swing cover. Screws: 3HAB3409-207 (M3x8).

Swing cover: 3HAC059676-001
: 3HAC056215-001 (used with protection
type Clean Room)
Swing cover, Clean Room
Swing cover, food grade lubrication
xx1300002551

4 Repair
Continued
Action Note
12 For robots with protection type Foundry Protection plug for lifting holes:
Plus (option 287-3) 3HAC4836-24
Replace if damaged.
xx1600001151

Room
to the joint of the swing cover.
smooth joint.
cover joint.
xx1600000217
14 For robots with protection type Foundry

Plus (option 287-3)
If required, fit two screws for protection.
xx1600001154

Note


4 Repair
Continued
Refitting the upper arm
Action Note
2 Fit guide pins to the axis-3 gear unit. Guide pin for upper arm: 3HAC049705-001
xx1400000027

(option 287-10)
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

Room robots.
xx1400000474

4 Repair
Continued
Action Note
4 Refit the upper arm to the lower arm and Screws: 3HAB3409-213 (M4x25).
secure with the upper arm screws and
washers. Do not tighten yet.
xx1400000028
Note


ing screws and washers.
xx1400000029
6 Tighten all screws. Tightening torque: 4.5 Nm.

4 Repair
Continued
Action Note
7 For robots with protection class IP67 Gasket on lower arm cover: 3HAC056725-
(option 287-10) 001
Plus (option 287-3)
Room
Check the lower arm cover gasket.
Replace if damaged.
xx1400000047
8 Refit the lower arm cover. Screws: 3HAB3409-207 (M3x8).

xx1300002528
Note


4 Repair
Continued
Action Note
9 For robots with protection class IP67 Gasket on lower arm cable housing:
(option 287-10) 3HAC044895-001
Plus (option 287-3)
Room
Check the cable housing gasket.
Replace if damaged.
xx1400000414

(option 287-10) Radial sealing: 3HAC024865-001
Plus (option 287-3)
Room
Check the axis-3 radial sealing and the M2
variseal sealing in the cable housing.
Replace if damaged.
Note
The M2 variseal sealing does not used for

robots with protection type Clean room and
with food grade lubrication.
Note

grease to the sealing when replacing the xx1400000473
placement. Replacement is detailed in Replacing the
axis-3 radial sealing and sealing ring on
CAUTION page 379.

Room robots.

4 Repair
Continued
Action Note
11 Refit the cable housing of the lower arm. Tightening torque: 3 Nm
xx1400000785

Room
to the joint of the cable housing of the lower
arm.
smooth joint.
cover joint.
Note xx1600000218
No sealing is required in the cavities of the

three lower screws highlighted with a ring
in the figure.

Plus (option 287-3)
xx1600001155

Note

4 Repair
Continued

Action Note
parts on page 144
(option 287-3)
Check the gasket.
Replace if damaged.
xx1400000476
287-10) 3HAC044894-001
(option 287-3)
plate.
Replace if damaged.
xx1400000457

4 Repair
Continued
Action Note
through them.
xx1400000025
xx1400000023

4 Repair
Continued
Action Note
287-10) 004
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

bots.
xx1400000454

4 Repair
Continued
Action Note
287-10) 3HAB3701-41
(option 287-3)
Replace if damaged.
Note

xx1400000753

Tip

xx1400000020

4 Repair
Continued
Action Note
xx1300002435
Note


xx1400000481

4 Repair
Continued
Action Note
• R2.ME2
• R2.MP2
xx1300002434
CAUTION

harness.
xx1400000021
xx1300002432

4 Repair
Continued
Action Note
xx1400001529

xx1400000482

location.
it in place.
See the figure.
xx1400001131

4 Repair
Continued
Action Note
287-10) 3HAC056726-001
(option 287-3)
Replace if damaged.
xx1400000424



4 Repair
Continued
Action Note
Screws: 3HAB3409-207 (M3x8).
xx1300002431
Note

(option 287-3) 3HAC4836-24
Replace if damaged.
xx1600001151

4 Repair
Continued
Action Note
xx1600000205
CAUTION

harness.
xx1300002430

Note


Action Note
1


parts on page 144

4 Repair
Continued
Action Note
287-10) 3HAC056728-001
(option 287-3)
Replace if damaged.
xx1400000475

1200 Type A
• R1.ME1-3
• R1.ME4-6
• R2.EIB
WARNING

1200 Type A
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING

xx1700000005

4 Repair
Continued
Action Note
xx1700000004
xx1300002427
Note


4 Repair
Continued
Action Note
arm.
xx1300002426

Note


Action Note
parts on page 144
xx1400000483

4 Repair
Continued
Action Note
Note

xx1400001472
Note

CAUTION

harness.
xx1300002424
xx1300002423

4 Repair
Continued
Action Note
xx1300002421
(3HAC049663-001).
Tip

xx1300002422
xx1400001133
xx1300002420

4 Repair
Continued
Action Note
xx1400000754

Note


Action Note
CAUTION

parts on page 144.
xx1300002371

4 Repair
Continued
Action Note
strap.
xx1300002494

Action Note
parts on page 144
Tip

xx1300002399

4 Repair
Continued
Action Note
Tip

xx1300002412
xx1400001471


4 Repair
Continued
Action Note
287-10)
(option 287-3)
housing.
Replace if damaged.
xx1300002398

001
lubrication
joint.
joint.
xx1600000214

4 Repair
Continued
Action Note
xx1300002413
xx1400000740

4 Repair
Continued
Action Note
287-10) 3HAC056724-001
(option 287-3) 3HAC044660-001
Replace if damaged.
xx1400000048

Replace if damaged.

4 Repair
Continued
Action Note
xx1300002400
Note


Note


Action Note
parts on page 144.
xx1400000738

4 Repair
Continued
Action Note
287-10)
(option 287-3)
1 Check the gasket.
xx1500000251
connectors.
xx1600001152
Action Note
CAUTION

xx1300002390

4 Repair
Continued

Action Note
• R3.MP5
• R3.ME5
CAUTION

parts on page 144.
xx1300002360
Action Note
(option 287-10)
Plus (option 287-3)
Room
Replace if damaged.
xx1400000034
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
Room
xx1300002349
xx1600001153
Note


Note


4 Repair
Continued
Action Note
(option 287-10) 3HAC056698-001
Plus (option 287-3) 3HAC056697-001
Room
Check the gasket.
Replace if damaged.
xx1400000477
CAUTION

cover.
xx1300000456
Note


Room
smooth joint.
cover joint.
xx1600000215

4 Repair
Continued
Action Note
4
CAUTION

.
Note

free cloth.

on page 737.
6
DANGER

page 28.

4 Repair
4.4.2 Replacing the signal lamp

The signal lamp is located as shown in the figure.
xx1300000455
Note

Signal lamp 3HAC16738-1
1200-7/0.7 ) IP40.
Replace if damaged.
1200-5/0.9 ) IP40.
Replace if damaged.

4 Repair
Continued

Replacing the signal lamp
Action Note
1
DANGER
Turn off all:

2
CAUTION
Always cut the paint with a knife and grind the paint
edge when disassembling parts. See Cut the paint
or surface on the robot before replacing parts on
page 144.
3 Remove the attachment screws of the upper arm

housing cover and lift the cover carefully until the
connectors of the signal lamp can be reached.
xx1300000456
4 Disconnect the connectors and remove the cover

from the robot.
5 Remove the nut from the lamp and pull out the lamp
from the cover.
6 Fit the new lamp to the cover and tighten the nut.
7 Find the lamp connectors in the cable harness in-
side the upper arm housing.
• Connect lamp connector R3.H1 to cable har-
ness connector H1.
• Connect lamp connector R3.H2 to cable har-
ness connector H2.
parts on page 144

4 Repair
Continued
Action Note
9 For robots with protection class IP67 (option 287- Housing cover gasket (IRB 1200-
10) 7/0.7 ): 3HAC056698-001
For robots with protection type Foundry Plus Housing cover gasket (IRB 1200-
(option 287-3) 5/0.9 ): 3HAC056697-001
Check the gasket.
Replace if damaged.
xx1400000477
10 Refit the cover on the upper arm housing. Screws: 3HAB3409-207 (M3x8).
Note

11 The signal lamp is now ready for use and is lit in

MOTORS ON mode.
Note


4 Repair
4.4.3 Replacing the tubular spare parts
Location of tubular spare parts

The tubular parts that are considered spare parts are located as shown in the
figure.
Tubular with sleeve Tubular cover Tubular cable hous- Tubular cable hous-
ing ing cover
xx1400000432 xx1400000433 xx1400000434 xx1400000435
3HAC059693-001 / 3HAC049656-001 3HAC059695-001 3HAC059694-001

3HAC059723-001 i :
3HAC059706-001: 3HAC056144-001 / 3HAC056143-001: 3HAC056145-001:
Used with protection 3HAC059708-001 ii : Used with protection Used with protection
type Clean Room. Used with protection type Clean Room. type Clean Room.
Used for robots with type Clean Room. Used for robots with Used for robots with
food grade lubrica- Used for robots with food grade lubrica- food grade lubrica-
tion. food grade lubrication. tion.
tion. Replace if damaged.
Replace if damaged.
i For information on which tubular to be ordered, see Spare part versions for the tubular on Type A
robots on page 805.
ii For information on which tubular cover for Clean Room robots to be ordered, see Spare part versions
for the tubular cover on Clean Room robots on page 806.
Note

Tubular with sleeve 3HAC059693-001 /
3HAC059723-001 i
Tubular with sleeve, Clean 3HAC059706-001 Used with protection type Clean
Room Room.
Tubular with sleeve, food grade Used for robots with food grade
Tubular cover 3HAC049656-001 Replace if damaged.
Tubular cover, Clean Room 3HAC056144-001 / Used with protection type Clean
ii
Tubular cover, food grade lubric- 3HAC059708-001 Room.
ation Used for robots with food grade
lubrication.
Replace if damaged.

4 Repair
Continued

IP40.
Replace if damaged.
Tubular cable housing 3HAC059695-001
Tubular cable housing, Clean 3HAC056143-001 Used with protection type Clean
Room Room.
Tubular cable housing, food Used for robots with food grade
IP40.
Replace if damaged.
Tubular cable housing cover 3HAC059694-001 Replace if damaged.
Tubular cable housing cover, 3HAC056145-001 Used with protection type Clean
Clean Room Room.
Tubular cable housing cover, Used for robots with food grade
food grade lubrication lubrication.
Replace if damaged.
cover IP40.
Replace if damaged.
Foundry Plus.
Replace if damaged.
i For information on which tubular to be ordered, see Spare part versions for the tubular on Type A
robots on page 805.
ii For information on which tubular cover for Clean Room robots to be ordered, see Spare part versions
for the tubular cover on Clean Room robots on page 806.

Guide pin for tilt unit (axis 5) 3HAC049706-001 Always use three guide pins together!
method. i

4 Repair
Continued

Cable straps -

Action Note
calibration:
Preparations before removing the tubular spare parts
Action Note

4 Repair
Continued
Action Note
xx1300002581
3
DANGER
Turn off all:

working area.
Replacing the tubular cable housing

Use these procedures to replace the tubular cable housing.

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note

287-10)
(option 287-3)
locking liquid.
figure.
xx1300002349
Note
Clean Room
figure.
xx1600001148

Action Note
1
CAUTION

parts on page 144.

nectors.
xx1300002390

4 Repair
Continued
Action Note
screws.
xx1300002391

Note

287-10)
(option 287-3)
xx1300002392
Action Note
Replace if damaged.
CAUTION

Room robots.
xx1300002396

4 Repair
Continued
Action Note
(option 287-10)
Plus (option 287-3)
Room
xx1300002608

housing.
M6x40.
xx1400000485

4 Repair
Continued
Action Note
xx1400000486

properly fitted.
Note


Action Note
parts on page 144
287-10)
(option 287-3)
xx1300002610
Note


4 Repair
Continued
Action Note
3HAC059695-001
Room
lubrication
xx1300002392

Note

Action Note
the M3 screws.
xx1400001401

4 Repair
Continued
Action Note
xx1400001402

Note

Action Note
CAUTION

xx1300002390
Action Note

4 Repair
Continued
Action Note
(option 287-10)
Plus (option 287-3)
Room
Replace if damaged.
xx1400000034
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
Room
xx1300002349
xx1600001153
Note


Note


4 Repair
Continued
Removing the tubular

Use these procedures to remove the tubular.

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

287-10)
(option 287-3)
locking liquid.
figure.
xx1300002349
Note
Clean Room
figure.
xx1600001148

4 Repair
Continued

Action Note
1
DANGER

off.

• R3.MP5
• R3.ME5
Tip

CAUTION

parts on page 144.
Action Note
1
DANGER

are turned off.
2
CAUTION


be moved sideways.
xx1300002350

4 Repair
Continued
Action Note
xx1300002351

connectors.
xx1300002390
xx1300002352
Removing the wrist

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
xx1300002353
xx1300002355
xx1300002356

move the plate.
xx1300002357

4 Repair
Continued
Action Note
xx1300002358

wrist.
connectors.

xx1300002611
Separating the tilt unit from the tubular

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
Note

287-10)
(option 287-3)
xx1400000774
4 Support the weight of the tilt unit and remove the

screws.
xx1300002469
5 Fit guide pins to the gearbox. Guide pin for tilt unit (axis 5):
3HAC049706-001
Always use three guide pins togeth-
er!
xx1400000775
6 Remove the tilt unit.
xx1300002470

4 Repair
Continued
Refitting the tubular

Use these procedures to refit the tubular.
Refitting the axis-5 and axis-6 drive unit

Action Note
parts on page 144
2 For robots with protection type Foundry Plus Protection cover for axis-6 turning
(option 287-3) disk: 3HAC044666-001
Check the protection cover for turning disk and T40 variseal sealing: 3HAC044641-
T40 variseal sealing. 012
Replace if damaged.
xx1600001126
287-10) 008
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

bots.
xx1300002493

surfaces of the drive unit.
Note

xx1400001404

4 Repair
Continued
Action Note
5 Fit guide pins to the axis-5 gearbox. Guide pin for tilt unit (axis 5):
3HAC049706-001
xx1300002568

Make sure the sealing to the tilt covers is intact
before the refitting.
xx1600000219
xx1600000220

4 Repair
Continued
Action Note
7 Refit the drive unit and secure with the screws Attachment screws: 3HAB3409-236
and washers. (M4x10).
Note
If there is glue on the screw, please clean it or

replace it with a new one.
xx1300002569
Note

8 Remove the guide pins and refit the remaining

screws and washers.
xx1300002570
9 Cross-tighten all the screws with torque 1 Nm first,

then with 2 Nm, with 4 Nm, and finally with 4.5
Nm.
Note

Action Note

4 Repair
Continued
Action Note
Replace if damaged.
CAUTION

Room robots.
xx1300002396

(option 287-10)
Plus (option 287-3)
Room
xx1300002608

housing.
M6x40.
xx1400000485

4 Repair
Continued
Action Note
xx1400000486

properly fitted.
Note


Action Note
parts on page 144
287-10)
(option 287-3)
xx1300002610
Note


4 Repair
Continued
Action Note
3HAC059695-001
Room
lubrication
xx1300002392

Note

Refitting the wrist

Action Note
parts on page 144

4 Repair
Continued
Action Note
connectors.

xx1300002611
xx1400000001

4 Repair
Continued
Action Note
pc)).
xx1400000002
Note

pcs)).
xx1400000003
Note


plate.
xx1300002356

4 Repair
Continued
Action Note
CAUTION

xx1300002355

• R3.Eth
• R3.CPCS
xx1300002353

Note


Action Note
1 Check that:
damages
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
xx1300002463
Note

Action Note
xx1300002351


screws.
xx1300002350

4 Repair
Continued
Action Note
Note

Action Note
the M3 screws.
xx1400001401
xx1400001402

Note


4 Repair
Continued
Action Note
CAUTION

xx1300002390

Action Note
• R3.MP5
• R3.ME5
CAUTION

parts on page 144.
xx1300002360
Action Note
(option 287-10)
Plus (option 287-3)
Room
Replace if damaged.
xx1400000034

4 Repair
Continued
Action Note
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
Room
xx1300002349
xx1600001153
Note


Note


4 Repair
Continued
Concluding procedures
Action Note
1 Clean and paint the joints that have been
Note

free cloth.

3
DANGER

page 28.

4 Repair
4.4.4 Replacing the axis-3 radial sealing and sealing ring
Location of the sealings

The axis-3 radial sealing and sealing ring are located as shown in the figure.
xx1400000336
Note

IP40.
Replace if damaged.
Foundry Plus.
Replace if damaged.

4 Repair
Continued

housing IP40.
Replace if damaged.
tion in tubular.
IP40.
Replace if damaged.
cover IP40.
Replace if damaged.

Axis-3 sealing assembly tool 3HAC049697-001 Used to refit the axis-3 radial sealing.
set

Cable straps -
Clean Room

4 Repair
Continued
Removing the sealings

Use these procedures to remove the axis-3 radial sealing and/or axis-3 sealing
ring.
Preparations before removing the sealings
Action Note
xx1300002581
2
DANGER
Turn off all:

working area.
3
CAUTION

4 Remove the wrist cover.
xx1300002389

4 Repair
Continued

Action Note
1
DANGER

off.

• R3.MP5
• R3.ME5
Tip

CAUTION

parts on page 144.
Action Note
1
DANGER

are turned off.

connectors.
CAUTION

xx1300002390

4 Repair
Continued

Action Note
1
DANGER

off.
CAUTION

parts on page 144.
xx1400000738

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
xx1300002400

4 Repair
Continued
Action Note
4 Remove the plate.
xx1300002413
disconnect them.
xx1300002412
xx1400001471

4 Repair
Continued
Action Note
xx1300002398
xx1300002399

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
CAUTION

xx1300000456
xx1300002494
Tip

when reconnecting.
xx1300002495

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
CAUTION

parts on page 144.
xx1300002420

Action Note
1
DANGER

off.

er.
CAUTION

parts on page 144.
xx1300002422

xx1300002421

4 Repair
Continued
Action Note
the motor.
xx1300002423

the two screws.
CAUTION

harness.
xx1300002424

Removing the lower arm cable housing
Action Note
1
DANGER

are turned off.
2
CAUTION

3 Pull the cable harness out from the upper

arm housing.

4 Repair
Continued
Action Note
by removing the screws.
xx1300002529
Removing the axis-3 radial sealing

Use this procedure if the axis-3 radial sealing is to be removed.
Action Note
1
DANGER

are turned off.
2
CAUTION


(option 287-10)
Plus (option 287-3)
Remove the M2 variseal sealing.
xx1400000473

4 Repair
Continued
Action Note
4 Remove the axis-3 radial sealing.
xx1400000334
Removing the axis-3 sealing ring

Use this procedure if the axis-3 sealing ring is to be removed.
Action Note
1
DANGER

are turned off.
2
CAUTION

3 Remove the screws.
xx1400000332

4 Repair
Continued
Action Note
4 Use screws in the two press out holes to
press the sealing ring out.
xx1400000333
Refitting the sealings

Use these procedures to refit the axis-3 radial sealing and/or axis-3 sealing ring.
Refitting the axis-3 sealing ring

Use this procedure if the axis-3 sealing ring needs to be refitted.
Action Note
(option 287-10)
Plus (option 287-3)
mounting surfaces of the sealing ring.
Note


4 Repair
Continued
Action Note
3 Refit the axis-3 sealing ring by securing the Tightening torque: 1.5 Nm
screws.
Note
Make sure to use the correct screw holes.

The two holes shown in the figure are only
used for pressing out the ring during remov-
al.
xx1400000333
xx1400000332

Note

Refitting the axis-3 radial sealing

Use this procedure if the axis-3 radial sealing needs to be refitted.
Action Note
parts on page 144
Apply a little grease to the sealing when replacing
the radial sealing and wipe clean after the replace-
ment.

4 Repair
Continued
Action Note
3 Fit the axis-3 radial sealing to the cable housing. Radial sealing: 3HAC024865-001
xx1400000334
4 Put the assembly tool on both sides of the cable Axis-3 sealing assembly tool set:
housing, circular part against the sealing, and 3HAC049697-001
then slowly press the sealing into the housing by
screwing the six screws (M6X50) into the plate
little by little.
Fit the circular part of the radial sealing fitting tool
against the radial sealing.
5 Fit the tool plate to the other side of the cable
housing with the six screws M6X50.
6 Screw the screws, little by little, to press the
sealing into place.
xx1400000335

4 Repair
Continued
Action Note
287-10) 006
(option 287-3)
Fit a new M2 variseal sealing.
CAUTION

bots.
xx1400000473
9 Check that the sealings are undamaged and

properly fitted.
Note

Refitting the lower arm cable housing
Action Note

4 Repair
Continued
Action Note
(option 287-10) 3HAC044895-001
Plus (option 287-3)
Room
Replace if damaged.
xx1400000414
3 For robots with protection class IP67 Radial sealing: 3HAC024865-001

(option 287-10) M2 variseal sealing: 3HAC044641-006
Plus (option 287-3)
Room
Check the radial sealing and the M2
variseal sealing.
Replace if damaged.
Note

Note

placement. Replacement of the radial sealing is de-
tailed in previous section.
CAUTION

Room robots.

4 Repair
Continued
Action Note
4 Refit the cable housing of the lower arm. Tightening torque: 4 Nm.
xx1300002529

Room
arm.
smooth joint.
cover joint.
Note xx1600000218

in the figure.

Note


Action Note
parts on page 144

4 Repair
Continued
Action Note
xx1400000483

Note

xx1400001472
Note

CAUTION

harness.
xx1300002424

4 Repair
Continued
Action Note
xx1300002423
xx1300002421
(3HAC049663-001).
Tip

xx1300002422
xx1400001133

4 Repair
Continued
Action Note
xx1300002420

xx1400000754

Note


4 Repair
Continued

Action Note
CAUTION

parts on page 144.
xx1300002371

strap.
xx1300002494

Action Note
parts on page 144
Tip

xx1300002399

4 Repair
Continued
Action Note
Tip

xx1300002412
xx1400001471


4 Repair
Continued
Action Note
287-10)
(option 287-3)
housing.
Replace if damaged.
xx1300002398

001
lubrication
joint.
joint.
xx1600000214

4 Repair
Continued
Action Note
xx1300002413
xx1400000740

4 Repair
Continued
Action Note
287-10) 3HAC056724-001
(option 287-3) 3HAC044660-001
Replace if damaged.
xx1400000048

Replace if damaged.

4 Repair
Continued
Action Note
xx1300002400
Note


Note


Action Note
parts on page 144.
xx1400000738

4 Repair
Continued
Action Note
287-10)
(option 287-3)
1 Check the gasket.
xx1500000251
connectors.
xx1600001152
Action Note
CAUTION

xx1300002390

4 Repair
Continued

Action Note
• R3.MP5
• R3.ME5
CAUTION

parts on page 144.
xx1300002360
Action Note
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
xx1300002389
Note


Note

Action Note
(option 287-10) 3HAC056698-001
Plus (option 287-3) 3HAC056697-001
Room
Check the gasket.
Replace if damaged.
xx1400000477

4 Repair
Continued
Action Note
CAUTION

cover.
xx1300000456
Note


Room
smooth joint.
cover joint.
xx1600000215
4
CAUTION

Note

free cloth.
5
DANGER

page 28.

4 Repair
4.4.5 Replacing the axis-2 mechanical stop
Location of the mechanical stop

The axis-2 mechanical stop is located as shown in the figure.
xx1400000389
Note

Mechanical stop set, axis 2 3HAC049637-001 Includes mechanical stop pin
(1 pc) and screws.

4 Repair
Continued

Replacing the mechanical stop

Use these procedures to remove the axis-2 mechanical stop.
Preparations before removing the mechanical stop
Action Note
1 Jog the robot to a position where the
mechanical stop is most easily accessed.
2
DANGER
Turn off all:

working area.
Replacing the axis-2 mechanical stop
Action Note
1
DANGER

are turned off.
2
CAUTION


4 Repair
Continued
Action Note
3 Remove the mechanical stop by removing
the screws.
4 Discard the old screws.
5 Refit and secure the new stop with the en-
closed screws.
xx1400000390
Screws: 9ADA624-45 (M5x16).

Note

6
DANGER

page 28.

4 Repair

xx1400000386
Note

(1 pc) and screws.


4 Repair
Continued

Use these procedures to replace the axis-3 mechanical stop.
Action Note
mechanical stops are most easily ac-
cessed.
2
DANGER
Turn off all:

working area.
Action Note
1
DANGER

are turned off.
2
CAUTION

3 Remove the mechanical stop to be re-

placed by removing the screws.
4 Discard the old screws.
closed screws.
xx1400000387
Screws: 9ADA624-45 (M5x16).

Note


4 Repair
Continued
Action Note
6
DANGER

page 28.

4 Repair
WARNING
The mechanical stop needs to be inspected immediately if it gets hit. Replace

the mechanical stop if damage is detected. Access to and inspection of the stop
requires disassembly of the robot according to this section.

The axis-4 mechanical stop is located inside the housing extender unit, as shown
in the figure.
xx1300002416
Note

Mechanical stop set 3HAC049652-001 Includes mechanical stop pin,
guide, slider and screws.

4 Repair
Continued

Foundry Plus.
Replace if damaged.
IP40.
Replace if damaged.
Room Room.
Replace if damaged.
PTFE film on lower arm cable 3HAC044710-001 Replace if damaged.
housing
IP40.
Replace if damaged.
cover
IP40.
Replace if damaged.
cover IP40.
Replace if damaged.

Used with protection class IP67.
Foundry Plus.
Flange sealing 3HAC026759-001 Sikaflex 521FC

4 Repair
Continued

Action Note
calibration:
Removing the mechanical stop

Use these procedures to remove the mechanical stop.
Preparations before removing the axis-4 mechanical stop
Action Note
xx1300002581

4 Repair
Continued
Action Note
3
DANGER
Turn off all:

working area.

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

287-10)
(option 287-3)
locking liquid.
figure.
xx1300002349
Note
Clean Room
figure.
xx1600001148

4 Repair
Continued

Action Note
1
DANGER

off.

• R3.MP5
• R3.ME5
Tip

CAUTION

parts on page 144.
Action Note
1
DANGER

are turned off.
2
CAUTION


be moved sideways.
xx1300002350

4 Repair
Continued
Action Note
xx1300002351

connectors.
xx1300002390
xx1300002352
Removing the wrist

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
xx1300002353
xx1300002355
xx1300002356

move the plate.
xx1300002357

4 Repair
Continued
Action Note
xx1300002358

wrist.
connectors.

xx1300002611

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
xx1300002400
4 Remove the plate.
xx1300002413

4 Repair
Continued
Action Note
disconnect them.
xx1300002412
xx1400001471
xx1300002398

4 Repair
Continued
Action Note
xx1300002399

Action Note
1
CAUTION

parts on page 144.
xx1300002373

xx1600000262
xx1300002372

4 Repair
Continued
Action Note
xx1300002374
Removing the axis-4 mechanical stop

Action Note
1
CAUTION

parts on page 144.
2 Remove the mechanical stop assembly from the

housing extender unit by removing the screws.
xx1300002415
Refitting the mechanical stop

Use these procedures to refit the mechanical stop.
Action Note

4 Repair
Continued
Action Note
(option 287-10)
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

Room robots.
xx1300002418
(option 287-10)
Plus (option 287-3)
Room
xx1400000438

tender unit.

4 Repair
Continued
Action Note
M6X50.
xx1400000436

xx1400000437

properly fitted.
unit.
Note


4 Repair
Continued
Refitting the axis-4 mechanical stop
Action Note
2 Fit the mechanical stop screw to the axis- Screws: 3HAB3409-231 (M4x8).
4 shaft. Tightening torque: 4 Nm.
xx1400000393
3 Fit the mechanical stop assembly to the Screws: 3HAB3409-216 (M5x12).

housing extender unit and secure with Tightening torque: 4 Nm.
screws.
xx1300002415
Note


Note


4 Repair
Continued

Action Note
parts on page 144
287-10)
(option 287-3)
Note

xx1300002613

xx1600000216

CAUTION

xx1300002374
Note

the housing.

4 Repair
Continued
Action Note
xx1300002372
(option 287-3) 001
xx1600000263
xx1300002373

Note


Action Note
parts on page 144

4 Repair
Continued
Action Note
Tip

xx1300002399
Tip

xx1300002412
xx1400001471


4 Repair
Continued
Action Note
287-10)
(option 287-3)
housing.
Replace if damaged.
xx1300002398

001
lubrication
joint.
joint.
xx1600000214

4 Repair
Continued
Action Note
xx1300002413
xx1400000740

4 Repair
Continued
Action Note
287-10) 3HAC056724-001
(option 287-3) 3HAC044660-001
Replace if damaged.
xx1400000048

Replace if damaged.

4 Repair
Continued
Action Note
xx1300002400
Note


Note

Refitting the wrist

Action Note
parts on page 144

4 Repair
Continued
Action Note
connectors.

xx1300002611
xx1400000001

4 Repair
Continued
Action Note
pc)).
xx1400000002
Note

pcs)).
xx1400000003
Note


plate.
xx1300002356

4 Repair
Continued
Action Note
CAUTION

xx1300002355

• R3.Eth
• R3.CPCS
xx1300002353

Note


Action Note
1 Check that:
damages
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
xx1300002463
Note

Action Note
xx1300002351


screws.
xx1300002350

4 Repair
Continued
Action Note
Note

Action Note
the M3 screws.
xx1400001401
xx1400001402

Note


4 Repair
Continued
Action Note
CAUTION

xx1300002390

Action Note
• R3.MP5
• R3.ME5
CAUTION

parts on page 144.
xx1300002360
Action Note
(option 287-10)
Plus (option 287-3)
Room
Replace if damaged.
xx1400000034

4 Repair
Continued
Action Note
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
Room
xx1300002349
xx1600001153
Note


Note


4 Repair
Continued
Action Note
Note

free cloth.

on page 737.
3
DANGER

page 28.

4 Repair
4.5.1 Replacing the base spare parts (base, axis-1 radial sealing, protection sleeve)
4.5 Swing and base
Location of the base spare parts

The base parts that are considered spare parts are located as shown in the figure.
Base Base, SafeMove 2-suppor- Radial sealing Cable protection
ted with dust lip sleeve inside
base
xx1400000395
xx1400000269
xx1400000396
3HAC059553-001 3HAC061270-001 3HAB3701-47 3HAC044690-001

Includes base machining, Used for IRB 1200 Type B. Not used with
axis-1 gear unit and axis-1 See Type B of IRB 1200 on protection class
AC motor with encoder in- page 798. IP40.
terface. Includes base machining, Replace if dam-
Incompatible with swing axis-1 gear unit and axis-1 aged.
3HAC049632-001. See AC motor with resolver in-
Spare part versions for the terface.
base on IP40/IP67 robots
on page 799.
3HAC059699-001 3HAC061271-001
Used with protection type Used for IRB 1200 Type B.
Clean Room. See Type B of IRB 1200 on
page 798.
Clean Room.
3HAC057906-001 3HAC061272-001
Used for robots with food Used for IRB 1200 Type B.
grade lubrication. See Type B of IRB 1200 on
page 798.
Used for robots with food
grade lubrication.

4 Repair
Continued
M2 variseal sealing Sealing ring (IP40) /

Sealing ring, gasket and V-ring (IP67)
xx1400000471 xx1400000471
3HAC044641-002 Sealing ring: 3HAC058568-001 (IP40)

Used with protection class IP67. Sealing ring, gasket and V-ring: 3HAC058001-
Used only on base 3HAC049628-001. See 001 (IP67)
Spare part versions for the base on IP40/IP67 Used with protection class IP67.
robots on page 799. Replace if damaged.
Replace if damaged.
Note

Base 3HAC059553-001 Includes base machining, axis-
1 gear unit and axis-1 AC motor
with encoder interface.
Incompatible with swing
Base, Clean Room 3HAC059699-001 Used with protection type Clean
Room.
Includes base machining, axis-
Base, food grade lubrication 3HAC057906-001 Used for robots with food grade
lubrication.

4 Repair
Continued

Base, SafeMove 2-supported 3HAC061270-001 Used for IRB 1200 Type B. See
Type B of IRB 1200 on page 798.
with resolver interface.
Base, Clean Room and Safe- 3HAC061271-001 Used for IRB 1200 Type B. See
Move 2-supported Type B of IRB 1200 on page 798.
Used with protection type Clean
Room.
Base, food grade lubrication and 3HAC061272-001 Used for IRB 1200 Type B. See
SafeMove 2-supported Type B of IRB 1200 on page 798.
lubrication.
IP40.
Replace if damaged.
Axis-1 sealing ring gasket 3HAC045685-001 Used with protection class IP67.
Only on axis-1 sealing ring ver-
sion 3HAC044676-001. See
Spare part versions for the axis-
1 sealing ring on IP40/IP67 ro-
bots on page 803. Replace if
damaged.
Axis-1 sealing ring gasket 3HAC058349-001 Not used with protection class
IP40.
damaged.
Foundry Plus.
3HAC058000-001 and
Replace if damaged.
Used only on base
Replace if damaged.

4 Repair
Continued

Sealing ring 3HAC058568-001 Used with protection class IP67.
Foundry Plus.
Used only on base
Replace if damaged.
Sealing ring, gasket and V-ring 3HAC058001-001 Used with protection class IP67.
Replace if damaged.
Protection plug 3HAC051199-001 Protection plug for the calibra-
tion hole in the swing (the hole
is used during calibration of axis
1 with the manual calibration
method).
Replace if damaged.
Cable protection sleeve inside 3HAC044690-001
base
O-ring 3HAB3772-86 Not used with protection class
IP40.
Replace if damaged.
Gasket for rear base cover 3HAC058566-001 Not used with protection class
IP40.
Replace if damaged.
Foundry Plus.
Replace if damaged.
tion in tubular.
IP40.
Replace if damaged.
cover IP40.
Replace if damaged.

Axis-1 sealing assembly tool 3HAC049692-001 Used to refit the axis-1 radial sealing.
set
method. i

4 Repair
Continued

Cable straps -
tact areas.
grade lubrication.
Grease 3HAC058065-001 Used for lubrication of radial
sealing surface between base
and swing.
Foundry Plus (option 287-3).
Clean Room.
Foundry Plus (option 287-3).

Action Note

4 Repair
Continued
Action Note
calibration:
Removing the cabling

Before the spare parts of the base can be removed, the cable harness must be
removed from upper arm and down to the base. Use these procedures to remove
the cabling in order to access the base spare parts.
Preparations before removing the cabling

Action Note
procedure.
xx1300002581
3
DANGER
Turn off all:

area.

4 Repair
Continued
Action Note
4
CAUTION

parts on page 144.
xx1300002389

Action Note
1
DANGER

off.

• R3.MP5
• R3.ME5
Tip

CAUTION

parts on page 144.

4 Repair
Continued
Action Note
1
DANGER

are turned off.

connectors.
CAUTION

xx1300002390

Action Note
1
DANGER

off.
CAUTION

parts on page 144.
xx1400000738

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
2
CAUTION

parts on page 144.
xx1300002400
4 Remove the plate.
xx1300002413

4 Repair
Continued
Action Note
disconnect them.
xx1300002412
xx1400001471
xx1300002398

4 Repair
Continued
Action Note
xx1300002399

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
CAUTION

xx1300000456
xx1300002494

4 Repair
Continued
Action Note
Tip

when reconnecting.
xx1300002495

Action Note
1
DANGER

off.

CAUTION

parts on page 144.
xx1300002420

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
er.
CAUTION

parts on page 144.
xx1300002422

xx1300002421

the motor.
xx1300002423

the two screws.
CAUTION

harness.
xx1300002424

4 Repair
Continued
Action Note

Action Note
1
DANGER

off.
2

3
CAUTION

parts on page 144.

CAUTION

CAUTION

xx1300002427

1200 Type A
• R1.ME1-3
• R1.ME4-6
• R2.EIB
lower arm.
1200 Type A
xx1300002428

4 Repair
Continued
Action Note
xx1700000004

• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
lower arm.
xx1700000005

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

housing.

4 Repair
Continued
Action Note
lower arm.
xx1300002426

CAUTION

harness.
xx1300002430

xx1400001130

xx1600000205

4 Repair
Continued
Action Note
ing the screws.
xx1300002431
xx1400001528
xx1300002432

4 Repair
Continued
Action Note
ing the screws.
CAUTION

harness.
xx1300002433

• R2.ME2
• R2.MP2
xx1300002434

package.
xx1300002435

4 Repair
Continued
Action Note
screws.
xx1400000020
Tip


package .
xx1400000023
Putting the robot on its side
Action Note
1
DANGER

are turned off.
2
CAUTION

3
CAUTION
The robot weighs .

IRB 1200-5/0.9: 54 kg
IRB 1200-7/0.7: 52 kg
accordingly!

4 Repair
Continued
Action Note
4 Run a roundsling between the housing and Roundsling, 2 m
the lower arm.
CAUTION
Put the sling on the lower arm side and not

on the cable arm side, which would damage
the robot.
xx1400000679
5
WARNING
The robot is likely to be mechanically un-

stable if not secured to the foundation!
6
CAUTION
The robot weighs .

IRB 1200-5/0.9: 54 kg
IRB 1200-7/0.7: 52 kg
accordingly!

4 Repair
Continued
Action Note
7 Loosen the robot from the foundation by
removing the foundation attachment
screws and put the robot on its side.
xx1400000680
Separating the arm system from base

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

screws.
Tip

xx1300000467

4 Repair
Continued
Action Note
xx1300000471
5 Pull out the base slightly and turn it aside.
Tip
Remember the cable layout in the base. The

cabling must be positioned and angled in the
same way during refitting.
xx1300000472
Removing the cable package from the axis-1 sealing ring
Action Note
1
CAUTION

parts on page 144.

and carefully run the cable package out from the
swing.
xx1300002438
3 Remove the swing (including arm system) com-

pletely from the base and lay it aside on a safe
location.

4 Repair
Continued
Action Note
4 Remove the cable bracket from the cabling, if the
cable package is to be replaced with a new spare
part.
xx1300002446
Replacing the radial sealing (IP67 and Foundry Plus)

First remove the cabling according to Removing the cabling on page 452, then use
this procedure to replace the axis-1 radial sealing.
The sealing is only used for robots with protection class IP67 (option 287-10) and
protection type Foundry Plus (option 287-3).
Removing the axis-1 radial sealing and M2 variseal sealing
Action Note
1
CAUTION

2 Raise the base into standing and put most

of the cable harness, including the sealing
ring bracket, into the base (in the space of
the protection sleeve).
3 Remove the M2 variseal sealing.
bots on page 799.
xx1400000780

4 Repair
Continued
Action Note
4 Remove the radial sealing.
xx1400000270
Refitting the axis-1 radial sealing and M2 variseal sealing
Action Note
Room
Apply a little grease to the sealing when
3 Fit the new sealing in its groove in the Radial sealing with dust lip: 3HAB3701-47
base.
xx1400000270

4 Repair
Continued
Action Note
4 Put the assembly tool against the axis-1 Axis-1 sealing assembly tool set:
gear and slowly press the sealing into the 3HAC049692-001
base by screwing the five screws (M10X35)
into the axis-1 gear screws little by little.
xx1400000271

6 Fit a new M2 variseal sealing in its groove
in the base.
bots on page 799.
CAUTION

Room robots.
xx1400000780
M2 variseal sealing: 3HAC044641-002

7 Check that the sealings are undamaged
and properly fitted.
Note


4 Repair
Continued
Replacing the M2 variseal sealing (IP67)

The M2 variseal sealing is only installed on base version 3HAC049628-001. See
Spare part versions for the base on IP40/IP67 robots on page 799.
this procedure to replace the M2 variseal sealing.
Note
The sealing is only used for robots with protection class IP67 (option 287-10) but
not for Clean Room robots. Do not fit the sealing to Clean Room robots.
Replacing the axis-1 M2 variseal sealing (IP67)
Action Note
1
CAUTION

2 Remove the sealing.

3 Clean Room robots: clean the joints that
have been opened. See Cut the paint or
surface on the robot before replacing parts
on page 144
4 Fit the new sealing in its groove in the
base.
CAUTION

Room robots. xx1400000472

Note


4 Repair
Continued
Replacing the cable protection sleeve

this procedure to replace the protection sleeve.
Replacing the cable protection sleeve
Action Note
1
CAUTION

parts on page 144.
2 Remove the cabling from the base.

3 Remove the screws.
xx1400000776
4 Pull up the protection sleeve.
xx1400000777

parts on page 144
6 Fit the new protection sleeve and secure with Tightening torque: 0.3 Nm.
screws.

4 Repair
Continued
Action Note
7 Apply grease on the inner surface of the protec-
tion sleeve, also on the bottom surface.
xx1400000778

Note

Replacing the base

Use these procedures to replace the base.
Action Note
1
DANGER

are turned off.
2
CAUTION


4 Repair
Continued
Action Note
3 Remove the bottom cover. Rear connector interface:
xx1300000469
xx1400000403

4 Repair
Continued
Action Note
4 Remove the axis-1 motor bracket. Rear connector interface:
xx1300000470
xx1400000404
5 Loosen the connectors from the bracket by

cutting the cable straps, and disconnect
the connectors.
xx1300002496

4 Repair
Continued
Removing the cable package from the base


base.
Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
xx1300002448

the rear.
xx1300002456

4 Repair
Continued
Cabling with bottom interface, and cabling routed from below (option 996-1)
Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
xx1400000405
4 Remove the brake release button from the base

cover.
6 Remove the cable bracket by removing the
screws.
xx1400000406

4 Repair
Continued
Action Note
7 Remove the bracket inside the base by removing
the screws.
xx1400000407

the bottom.
xx1400000411
Removing the axis-1 radial sealing and M2 variseal sealing
Action Note
1
CAUTION

2 Raise the base into standing and put most

of the cable harness, including the sealing
ring bracket, into the base (in the space of
the protection sleeve).

4 Repair
Continued
Action Note
3 Remove the M2 variseal sealing.
bots on page 799.
xx1400000780
4 Remove the radial sealing.
xx1400000270
Replacing the base
Action Note
1
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
2 Move the protection sleeve from the old base to Tightening torque: 0.3 Nm.
the new.
xx1400000776
3 Move the axis-1 mechanical stop set from the old Tightening torque: 12 Nm.
base to the new.
Replace if damaged.
xx1400000392
Refitting the axis-1 radial sealing and M2 variseal sealing
Action Note
Room
Apply a little grease to the sealing when

4 Repair
Continued
Action Note
3 Fit the new sealing in its groove in the Radial sealing with dust lip: 3HAB3701-47
base.
xx1400000270
4 Put the assembly tool against the axis-1 Axis-1 sealing assembly tool set:
gear and slowly press the sealing into the 3HAC049692-001
base by screwing the five screws (M10X35)
into the axis-1 gear screws little by little.
xx1400000271

4 Repair
Continued
Action Note
6 Fit a new M2 variseal sealing in its groove
in the base.
bots on page 799.
CAUTION

Room robots.
xx1400000780

7 Check that the sealings are undamaged
and properly fitted.
Note

Refitting the cable package to the base


base.
Action Note
parts on page 144

4 Repair
Continued
Action Note
287-10) 3HAC058566-001
(option 287-3)
Check the gasket on the base cover.
Replace if damaged.
xx1400000741

base, through the rear.
5 Refit the base cover with the attachment screws. Screws: 3HAB3409-212 (M4x16).
xx1300002448
Note


in the figure.
xx1400000480

Note

4 Repair
Continued
Cabling with bottom interface, cabling routed from below (option 996-1)
Action Note
parts on page 144
base, through the bottom.
3 Refit the bracket inside the base with the screws. Tightening torque: 1.5 Nm.
xx1400000407
4 Refit the cable bracket with the screws. Tightening torque: 1.5 Nm.
xx1400000406
287-10) 3HAC058566-001
(option 287-3)
Check the gasket of the base cover.
Replace if damaged.
xx1400000413

7 Refit the brake release button to the base cover.

4 Repair
Continued
Action Note
8 Refit the base cover. Screws: 3HAB3409-212 (M4x16).
xx1400000405
Note


in the figure.
xx1400000480

Note

Refitting the cabling

Use these procedures to refit the cabling, after the base part in question has been
replaced.
Refitting the cable package to the axis-1 sealing ring
Action Note
parts on page 144
Replace if damaged. 001 / 3HAC058568-001 i

4 Repair
Continued
Action Note
287-10)
xx1600001125
287-10) 3HAC044676-001:
or 3HAC058568-001: 3HAC045685-001
(option 287-3)
Replace if damaged. xx1400000458

3HAC058568-001:
3HAC058349-001
xx1600001149

or 3HAC058568-001:
(option 287-3)

3HAC058568-001:
xx1600001150

4 Repair
Continued
Action Note
xx1400000456
7 Refit the cable bracket to the cabling, if removed. Tightening torque: 1 Nm.
Use Loctite 243 on the screw threads.
xx1300002446
8 Refit the axis-1 sealing ring to the swing and Tightening torque: 1.5 Nm.
carefully run the cabling into the swing.
xx1300002438

Note


4 Repair
Continued
Assembling the swing and base
Action Note
2 Check the axis-1 radial sealing and the M2 Radial sealing with dust lip: 3HAB3701-47
variseal sealing in the base. M2 variseal sealing: 3HAC044641-002
Replace if damaged.
Note

grease to the sealing when replacing the
placement.
bots on page 799.
xx1400000472
CAUTION Replacement is detailed in Replacing the

base spare parts (base, axis-1 radial seal-
Do not fit M2 variseal sealing on Clean ing, protection sleeve) on page 447.
Room robots.
3 For robots with protection class IP67 Grease: 3HAC058065-001.

(option 287-10)
Plus (option 287-3)
Apply grease to the radial sealing surface.
xx1600000170

4 Repair
Continued
Action Note
4 Fit the guide pins to the drive unit. Guide pin for axis-1 gear unit:
3HAC049703-001
xx1300002566

5 Refit the swing to the base with guidance
from the guide pins while running the
cabling up through the swing.
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.
6 Secure with attachment screws and wash- Screws: 3HAB3409-52 (M10x35).

ers, but do not tighten yet.
xx1300002567
Note


4 Repair
Continued
Action Note
ing attachment screws and washers.
xx1300000523

9 For robots with protection class IP67 Gasket on top swing cover: 3HAC056696-
(option 287-10) 001
Plus (option 287-3)
Room
Check the gasket.
Replace if damaged.
xx1400000425

4 Repair
Continued
Action Note
10 Refit the swing top cover with the screws. Cover on top of swing: 3HAC059679-001
Replace if damaged. : 3HAC056133-001 (used with protection
type Clean Room)
Cover on top of swing, food grade lubrica-
tion
Screws: 3HAB3409-209 (M3x20).
xx1300000467
Note


Note

Action Note

4 Repair
Continued
Action Note
2 Reconnect the connectors and secure the
connectors to the bracket with cable straps.
xx1300002496
3 Refit the axis-1 motor bracket. Tightening torque: 1.5 Nm.

xx1300000470
xx1400000404

4 Repair
Continued
Action Note
4 For robots with protection class IP67 O-ring: 3HAB3772-86
(option 287-10)
Plus (option 287-3)
Room
Check the O-ring.
Replace if damaged.
xx1400000412
5 Refit the bottom cover. Screws: 3HAB3409-207 (M3x8).

xx1300000469
xx1400000403
Note


4 Repair
Continued
Action Note
Note

Securing the robot to the foundation

Action Note
1
CAUTION
The robot weighs .

IRB 1200-5/0.9: 54 kg
IRB 1200-7/0.7: 52 kg
All lifting accessories used must be
sized accordingly!
2 For robots with: O-ring: 3HAB3772-141

protection class IP67 (option 287-10), For robots with protection class IP67 (option
protection type Foundry Plus (option 287-10)
287-3), Used with protection type Foundry Plus
and manipulator cables routed from For robots with protection type Clean Room
below (option 996-1) For robots with food grade lubrication
Check the gasket at the bottom of the Used with manipulator cables routed from be-
base. low (option 996-1)
Replace if damaged.
xx1500000241
3 Raise the robot to standing and secure Attachment screws: M12x35 (robot installation
to the foundation with the attachment directly on foundation), quality: 8.8.
screws and washers. Washers: 13 x 20 x 2, steel hardness class
300HV.
CAUTION
Pin: 2 pcs, D6x20, ISO 2338 - 6m6x20 - A1.
Always cut the paint with a knife and Tightening Torque: 55 Nm ± 5 Nm.
grind the paint edge when disas-
sembling parts. See Cut the paint or
surface on the robot before replacing
parts on page 144.

4 Repair
Continued

Action Note
parts on page 144
(option 287-3)
Check the gasket.
Replace if damaged.
xx1400000476
287-10) 3HAC044894-001
(option 287-3)
plate.
Replace if damaged.
xx1400000457

4 Repair
Continued
Action Note
through them.
xx1400000025
xx1400000023

4 Repair
Continued
Action Note
287-10) 004
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

bots.
xx1400000454

4 Repair
Continued
Action Note
287-10) 3HAB3701-41
(option 287-3)
Replace if damaged.
Note

xx1400000753

Tip

xx1400000020

4 Repair
Continued
Action Note
xx1300002435
Note


xx1400000481

4 Repair
Continued
Action Note
• R2.ME2
• R2.MP2
xx1300002434
CAUTION

harness.
xx1400000021
xx1300002432

4 Repair
Continued
Action Note
xx1400001529

xx1400000482

location.
it in place.
See the figure.
xx1400001131

4 Repair
Continued
Action Note
287-10) 3HAC056726-001
(option 287-3)
Replace if damaged.
xx1400000424



4 Repair
Continued
Action Note
Screws: 3HAB3409-207 (M3x8).
xx1300002431
Note

(option 287-3) 3HAC4836-24
Replace if damaged.
xx1600001151

4 Repair
Continued
Action Note
xx1600000205
CAUTION

harness.
xx1300002430

Note


Action Note
1


parts on page 144

4 Repair
Continued
Action Note
287-10) 3HAC056728-001
(option 287-3)
Replace if damaged.
xx1400000475

1200 Type A
• R1.ME1-3
• R1.ME4-6
• R2.EIB
WARNING

1200 Type A
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING

xx1700000005

4 Repair
Continued
Action Note
xx1700000004
xx1300002427
Note


4 Repair
Continued
Action Note
arm.
xx1300002426

Note


Action Note
parts on page 144
xx1400000483

4 Repair
Continued
Action Note
Note

xx1400001472
Note

CAUTION

harness.
xx1300002424
xx1300002423

4 Repair
Continued
Action Note
xx1300002421
(3HAC049663-001).
Tip

xx1300002422
xx1400001133
xx1300002420

4 Repair
Continued
Action Note
xx1400000754

Note


Action Note
CAUTION

parts on page 144.
xx1300002371

4 Repair
Continued
Action Note
strap.
xx1300002494

Action Note
parts on page 144
Tip

xx1300002399

4 Repair
Continued
Action Note
Tip

xx1300002412
xx1400001471


4 Repair
Continued
Action Note
287-10)
(option 287-3)
housing.
Replace if damaged.
xx1300002398

001
lubrication
joint.
joint.
xx1600000214

4 Repair
Continued
Action Note
xx1300002413
xx1400000740

4 Repair
Continued
Action Note
287-10) 3HAC056724-001
(option 287-3) 3HAC044660-001
Replace if damaged.
xx1400000048

Replace if damaged.

4 Repair
Continued
Action Note
xx1300002400
Note


Note


Action Note
parts on page 144.
xx1400000738

4 Repair
Continued
Action Note
287-10)
(option 287-3)
1 Check the gasket.
xx1500000251
connectors.
xx1600001152
Action Note
CAUTION

xx1300002390

4 Repair
Continued

Action Note
• R3.MP5
• R3.ME5
CAUTION

parts on page 144.
xx1300002360
Action Note
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
xx1300002389
Note


Note

Action Note
(option 287-10) 3HAC056698-001
Plus (option 287-3) 3HAC056697-001
Room
Check the gasket.
Replace if damaged.
xx1400000477

4 Repair
Continued
Action Note
CAUTION

cover.
xx1300000456
Note


Room
smooth joint.
cover joint.
xx1600000215

Note

free cloth.

6
DANGER

page 28.

4 Repair
4.5.2 Replacing the swing spare parts (swing, axis-2 radial sealing)
Location of the swing spare parts

The swing parts that are considered spare parts are located as shown in the figures.
Swing Swing cover
xx1400000442 xx1400000443
3HAC059554-001 3HAC059676-001
3HAC059700-001 3HAC056215-001
Used with protection type Clean Room. Used with protection type Clean Room.
Used for robots with food grade lubrication. Used for robots with food grade lubrication.
Replace if damaged.
Cable housing of the swing Cable housing cover of the Radial sealing with dust lip
swing
xx1400000446 xx1400000445 xx1400000444
3HAC059677-001 3HAC059678-001 3HAB3701-41

3HAC056213-001 3HAC056214-001 Not used with protection class
IP40.
Used with protection type Used with protection type
Clean Room. Clean Room. Replace if damaged.
Used for robots with food Used for robots with food
grade lubrication. grade lubrication.
Replace if damaged. Replace if damaged.

4 Repair
Continued
Note

Swing 3HAC059554-001 If the swing 3HAC049632-001 or
3HAC058000-001 is previously
installed on the robot, also a
new sealing ring and, for IP67
and Foundry Plus, a gasket and
a V-ring is required. See Spare
Swing, Clean Room 3HAC059700-001 Used with protection type Clean
Swing, food grade lubrication Room.
lubrication.
Axis-1 sealing ring 3HAC044676-001 / Replace if damaged.
3HAC058568-001 i
Axis-1 sealing ring gasket 3HAC045685-001 Used with protection class IP67.
damaged.
Axis-1 sealing ring gasket 3HAC058349-001 Not used with protection class
IP40.
damaged.
Sealing ring, gasket and V-ring 3HAC058001-001 Used with protection class IP67.
Replace if damaged.
Foundry Plus.
3HAC058000-001 and
Replace if damaged.
Cable protection 3HAC044691-001 Replace if damaged.
Torx countersunk head screw 3HAC14286-4 Replace if damaged.
M3x5
Cover on top of swing 3HAC059679-001 Replace if damaged.

4 Repair
Continued

Cover on top of swing, Clean 3HAC056133-001 Used with protection type Clean
Room Room.
Cover on top of swing, food Used for robots with food grade
Replace if damaged.
Gasket on top swing cover 3HAC056696-001 Not used with protection class
IP40.
Replace if damaged.
Swing cover 3HAC059676-001 Replace if damaged.
Swing cover, Clean Room 3HAC056215-001 Used with protection type Clean
Swing cover, food grade lubrica- Room.
tion Used for robots with food grade
lubrication.
Replace if damaged.
IP40.
Replace if damaged.
IP40.
Replace if damaged.
Cable housing of the swing 3HAC059677-001 Replace if damaged.
Cable housing of the swing, 3HAC056213-001 Used with protection type Clean
Clean Room Room.
Cable housing of the swing, food Used for robots with food grade
Replace if damaged.
swing
Replace if damaged.
tion class IP40.
Replace if damaged.
Foundry Plus.
Replace if damaged.
Foundry Plus.
Replace if damaged.

4 Repair
Continued

tion in tubular.
IP40.
Replace if damaged.
cover IP40.
Replace if damaged.
1200-7/0.7 ) IP40.
Replace if damaged.
1200-5/0.9 ) IP40.
Replace if damaged.

method. i
Cable straps -

4 Repair
Continued

Clean Room

Action Note
calibration:
Removing the swing parts

Use these procedures to remove the swing spare parts.
Preparations before removing the swing spare parts
Action Note

4 Repair
Continued
Action Note
xx1300002581
3
DANGER
Turn off all:

working area.
4
CAUTION

xx1300002389

4 Repair
Continued

Action Note
1
DANGER

off.

• R3.MP5
• R3.ME5
Tip

CAUTION

parts on page 144.
Action Note
1
DANGER

are turned off.

connectors.
CAUTION

xx1300002390

4 Repair
Continued

Action Note
1
DANGER

off.
CAUTION

parts on page 144.
xx1400000738

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
xx1300002400

4 Repair
Continued
Action Note
4 Remove the plate.
xx1300002413
disconnect them.
xx1300002412
xx1400001471

4 Repair
Continued
Action Note
xx1300002398
xx1300002399

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
CAUTION

xx1300000456
xx1300002494
Tip

when reconnecting.
xx1300002495

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
CAUTION

parts on page 144.
xx1300002420

Action Note
1
DANGER

off.

er.
CAUTION

parts on page 144.
xx1300002422

xx1300002421

4 Repair
Continued
Action Note
the motor.
xx1300002423

the two screws.
CAUTION

harness.
xx1300002424


Action Note
1
DANGER

off.
2

3
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
CAUTION

CAUTION

xx1300002427

1200 Type A
• R1.ME1-3
• R1.ME4-6
• R2.EIB
lower arm.
1200 Type A
xx1300002428

xx1700000004

4 Repair
Continued
Action Note
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
lower arm.
xx1700000005

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

housing.
lower arm.
xx1300002426

4 Repair
Continued
Action Note
CAUTION

harness.
xx1300002430

xx1400001130

xx1600000205

ing the screws.
xx1300002431

4 Repair
Continued
Action Note
xx1400001528
xx1300002432

ing the screws.
CAUTION

harness.
xx1300002433

4 Repair
Continued
Action Note
• R2.ME2
• R2.MP2
xx1300002434

package.
xx1300002435

screws.
xx1400000020
Tip


4 Repair
Continued
Action Note
package .
xx1400000023
Fitting lifting equipment to the upper and lower arm

Action Note
1
CAUTION
The lower and upper arms together weigh 30 kg.

All lifting accessories used must be sized accord-
ingly!

parts on page 144
3 Fit lifting slings to the upper and lower arm. Roundsling, 2 m
Note

Action Note
1
DANGER

are turned off.
2
CAUTION


4 Repair
Continued
Action Note
xx1300002551

ers.
WARNING

secured.
xx1300002552

4 Repair
Continued
Action Note
3HAC049704-001
xx1300002563
Tip

evenly.
xx1300002553
Removing the swing

Use this procedure if replacing the swing.
Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
screws.
Tip

xx1400000447
4 Remove the swing attachment screws and wash-

ers.
xx1400000448
5 Lift the swing upwards to access the axis-1 seal-

ing ring.
CAUTION

sealing ring fitted to the swing! The swing can not
be removed completely until the axis-1 sealing
ring is removed, as shown in following step.
xx1400000449

4 Repair
Continued
Action Note
and carefully run the cabling out from the swing.
xx1400000455
Removing the axis-2 radial sealing (IP67 and Foundry Plus)

Use this procedure if replacing the axis-2 radial sealing.
The sealing is only used for robots with protection class IP67 (option 287-10) and
with protection type Foundry Plus (option 287-3).
Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
3 Remove the axis-2 radial sealing from the cable
housing.
xx1400000450
Refitting the swing spare parts

Use these procedures to refit the swing spare parts.
Refitting the swing

Use this procedure if replacing the swing.
Action Note
parts on page 144
287-10)
(option 287-3)
On swing version 3HAC058000-001:
Add sealant to the swing groove.
xx1600000053

4 Repair
Continued
Action Note
287-10)
xx1600001125
287-10) 3HAC044676-001:
or 3HAC058568-001: 3HAC045685-001
(option 287-3)
Replace if damaged.

3HAC058568-001:
3HAC058349-001
xx1600001149

or 3HAC058568-001:
(option 287-3)

3HAC058568-001:
xx1600001150

4 Repair
Continued
Action Note
xx1400000456
7 Fit the axis-1 sealing ring to the swing with the Axis-1 sealing ring: 3HAC044676-
screws and carefully run the cabling out up 001 / 3HAC058568-001 i
through the swing. Tightening torque: 1.5 Nm.
xx1400000455

4 Repair
Continued
Action Note
8 Lower the swing down into place while at the
same time guiding the cabling through the cable
hole.
xx1400000449
9 Refit the swing attachment screws and washers. Screws: 3HAB3409-52 (M10x35).
xx1400000448
Note


4 Repair
Continued
Action Note
10 For robots with protection class IP67 (option Gasket on top swing cover:
287-10) 3HAC056696-001
(option 287-3)
Check the gasket.
Replace if damaged.
xx1400000425
11 Refit the swing top cover with the screws. Cover on top of swing:
Cover on top of swing, food grade
lubrication
Screws: 3HAB3409-209 (M3x20).
xx1400000447
Note


Note


4 Repair
Continued
Refitting the axis-2 radial sealing (IP67, Foundry Plus, Clean Room, food grade lubrication)
Use this procedure if replacing the axis-2 radial sealing.
The sealing is only used for robots with protection class IP67 (option 287-10), with
protection type Foundry Plus (option 287-3), with protection type Clean Room and
Action Note
parts on page 144
Apply a little grease to the sealing and wipe clean
after the refitting.
3 Fit the axis-2 radial sealing into the cable housing. Radial sealing with dust lip:
3HAB3701-41
xx1400000450

4 Repair
Continued
Action Note
4 Fit the circular part of the radial sealing fitting tool Axis-2 sealing assembly tool set:
against the radial sealing. 3HAC049694-001
5 Fit the tool plate to the other side of the cable
housing with the six screws M6X50.
xx1400000451
6 Screw the screws, little by little, to press the

sealing into place.
xx1400000452

8 Check that the sealing is undamaged and properly
fitted.
Note


4 Repair
Continued
Fitting lifting equipment to the upper and lower arm

Action Note
1
CAUTION

ingly!

parts on page 144
3 Fit lifting slings to the upper and lower arm. Roundsling, 2 m
Note

Action Note
Replace if damaged.
xx1300002556

4 Repair
Continued
Action Note
Note

xx1400001403
3HAC049704-001
xx1300002562

4 Repair
Continued
Action Note
(option 287-10)
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

Room robots.
xx1400000453

xx1300002563

4 Repair
Continued
Action Note
xx1300002564
Note


quid Loctite 243.
xx1300002565

4 Repair
Continued
Action Note
(option 287-10)
Plus (option 287-3)
Room
Replace if damaged.
xx1400000007

type Clean Room)
xx1300002551

4 Repair
Continued
Action Note
Replace if damaged.
xx1600001151

Room
smooth joint.
cover joint.
xx1600000217

Plus (option 287-3)
xx1600001154

Note


4 Repair
Continued

Action Note
parts on page 144
(option 287-3)
Check the gasket.
Replace if damaged.
xx1400000476
287-10) 3HAC044894-001
(option 287-3)
plate.
Replace if damaged.
xx1400000457

4 Repair
Continued
Action Note
through them.
xx1400000025
xx1400000023

4 Repair
Continued
Action Note
287-10) 004
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

bots.
xx1400000454

4 Repair
Continued
Action Note
287-10) 3HAB3701-41
(option 287-3)
Replace if damaged.
Note

xx1400000753

Tip

xx1400000020

4 Repair
Continued
Action Note
xx1300002435
Note


xx1400000481

4 Repair
Continued
Action Note
• R2.ME2
• R2.MP2
xx1300002434
CAUTION

harness.
xx1400000021
xx1300002432

4 Repair
Continued
Action Note
xx1400001529

xx1400000482

location.
it in place.
See the figure.
xx1400001131

4 Repair
Continued
Action Note
287-10) 3HAC056726-001
(option 287-3)
Replace if damaged.
xx1400000424



4 Repair
Continued
Action Note
Screws: 3HAB3409-207 (M3x8).
xx1300002431
Note

(option 287-3) 3HAC4836-24
Replace if damaged.
xx1600001151

4 Repair
Continued
Action Note
xx1600000205
CAUTION

harness.
xx1300002430

Note


Action Note
1


parts on page 144

4 Repair
Continued
Action Note
287-10) 3HAC056728-001
(option 287-3)
Replace if damaged.
xx1400000475

1200 Type A
• R1.ME1-3
• R1.ME4-6
• R2.EIB
WARNING

1200 Type A
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING

xx1700000005

4 Repair
Continued
Action Note
xx1700000004
xx1300002427
Note


4 Repair
Continued
Action Note
arm.
xx1300002426

Note


Action Note
parts on page 144
xx1400000483

4 Repair
Continued
Action Note
Note

xx1400001472
Note

CAUTION

harness.
xx1300002424
xx1300002423

4 Repair
Continued
Action Note
xx1300002421
(3HAC049663-001).
Tip

xx1300002422
xx1400001133
xx1300002420

4 Repair
Continued
Action Note
xx1400000754

Note


Action Note
CAUTION

parts on page 144.
xx1300002371

4 Repair
Continued
Action Note
strap.
xx1300002494

Action Note
parts on page 144
Tip

xx1300002399

4 Repair
Continued
Action Note
Tip

xx1300002412
xx1400001471


4 Repair
Continued
Action Note
287-10)
(option 287-3)
housing.
Replace if damaged.
xx1300002398

001
lubrication
joint.
joint.
xx1600000214

4 Repair
Continued
Action Note
xx1300002413
xx1400000740

4 Repair
Continued
Action Note
287-10) 3HAC056724-001
(option 287-3) 3HAC044660-001
Replace if damaged.
xx1400000048

Replace if damaged.

4 Repair
Continued
Action Note
xx1300002400
Note


Note


Action Note
parts on page 144.
xx1400000738

4 Repair
Continued
Action Note
287-10)
(option 287-3)
1 Check the gasket.
xx1500000251
connectors.
xx1600001152
Action Note
CAUTION

xx1300002390

4 Repair
Continued

Action Note
• R3.MP5
• R3.ME5
CAUTION

parts on page 144.
xx1300002360
Action Note
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
xx1300002389
Note


Note

Action Note
(option 287-10) 3HAC056698-001
Plus (option 287-3) 3HAC056697-001
Room
Check the gasket.
Replace if damaged.
xx1400000477

4 Repair
Continued
Action Note
CAUTION

cover.
xx1300000456
Note


Room
smooth joint.
cover joint.
xx1600000215

on page 737.
5
CAUTION

Note

free cloth.

4 Repair
Continued
Action Note
6
DANGER

page 28.

4 Repair

xx1400000391
Note

(1 pc), washer and screw.


4 Repair
Continued

Use these procedures to remove the axis-1 mechanical stop.
Action Note
mechanical stop is most easily accessed.
2
DANGER
Turn off all:

working area.
Action Note
1
DANGER

are turned off.

3 Remove the mechanical stop by removing
the screw.
4 Discard the old screw and washer.
closed screw and washer.
6
CAUTION

before replacing parts on page 144. xx1400000392
Screw: 9ADA183-37 (M8x25).

Note
robot free from particles with spirit on a lint Note
free cloth.

4 Repair
Continued
Action Note
7
DANGER

page 28.

4 Repair
4.6.1 Replacing the axis-1 gear unit
4.6 Motors and gearboxes
4.6.1 Replacing the axis-1 gear unit
Part of complete base

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 447.

4 Repair
4.6.2 Replacing the axis-2 drive unit
Location of the drive unit

The axis-2 drive unit is located as shown in the figure.
xx1300002547
Note

4 Repair
Continued

Drive unit 3HAC049645-001 Includes axis-2 gearbox, AC
motor with encoder interface,
motor adapter and O-ring
(3HAC048939-001).
Drive unit, food grade lubrication 3HAC057903-001 Used for robots with food grade
lubrication.
Includes axis-2 gearbox, AC
(3HAC048939-001).
Drive unit, SafeMove 2-suppor- 3HAC061273-001 Used for IRB 1200 Type B. See
ted Type B of IRB 1200 on page 798.
motor with resolver interface,
(3HAC048939-001).
Drive unit, food grade lubrication 3HAC061274-001 Used for IRB 1200 Type B. See
and SafeMove 2-supported. Type B of IRB 1200 on page 798.
lubrication.
(3HAC048939-001).
Foundry Plus.
Replace if damaged.
IP40.
Replace if damaged.
tion class IP40.
Replace if damaged.

method. i

4 Repair
Continued
Cable straps -
Harmonic grease 4B No. 2 3HAC037302-001 Total amount: 60 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.
LUBRIPLATE SYNXTREME FG-0 3HAC043771-001 Total amount: 60 g.
Used to lubricate the gearbox of
robots with food grade lubrica-
tion.
tion.

Action Note
calibration:

4 Repair
Continued
Removing the drive unit

Use these procedures to remove the axis-2 drive unit.
Preparations before removing the axis-2 drive unit

Action Note
procedure.
xx1300002581
3
DANGER
Turn off all:

area.
4
CAUTION

ingly!
5 Fit a roundsling to the upper arm to support the

weight of the upper and lower arm. (no force)
Loosening the cabling in the swing
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
2
CAUTION


Room
Follow the procedure specified in Remov-
ing the swing sealing plug on page 150.
xx1600000205
4 Remove the cable housing cover of the

swing by removing the screws.
xx1300002431

4 Repair
Continued
Action Note
xx1400001528
xx1300002432

• R2.ME2
• R2.MP2
xx1300002434

4 Repair
Continued
Action Note
8 Pull out the cable harness slightly from the
lower arm housing.
Note
The cabling is still connected inside the

robot, so be careful not to strain the cables!
xx1300002548
9 Loosen the cable housing of the swing by

removing the screws, and tilt it outwards.
CAUTION
Make sure that the sealing in the cable

housing does not get damaged when the
cable housing is hanging on the cable.
xx1300002549
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
2
CAUTION

xx1300002551

ers.
WARNING

secured.
xx1300002552

4 Repair
Continued
Action Note
3HAC049704-001
xx1300002563
Tip

evenly.
xx1300002553
Action Note
1
DANGER

are turned off.
2
CAUTION


4 Repair
Continued
Action Note
3
CAUTION
The lower and upper arms together weigh

30 kg.
accordingly!
4 If there is enough space on the site, lay

down the lower arm on a workbench. Make
sure to support the gravity center of the
lower arm.
If the site is cramp, the procedure can be
performed having the lower arm hanging
in the lifting slings.
If removing the axis-2 drive unit from a
hanging lower arm, it is best performed by
two persons working together:
• Person 2: Remove the drive unit
screws according to step below.
xx1300002554
5 Remove the grey screws from the drive
unit.
WARNING
Keep the eight black screws fitted. They

hold the gearbox together. Removing them
can damage the gearbox severely.
6 Insert two M4 screws to the press out holes

and press out the drive unit.
xx1400000008
xx1300002555

4 Repair
Continued
Refitting the drive unit

Use these procedures to refit the axis-2 drive unit.
Action Note
grade lubrication).
(option 287-10)
Plus (option 287-3)
mounting surfaces of the lower arm.
Note

xx1400000006

4 Repair
Continued
Action Note
4 Carefully insert the complete drive unit.
Note
Pay attention to the relative position

between the motor connector block and
the lower arm, so that the drive unit is posi-
tioned correctly inside the lower arm.
xx1300002580
xx1400000795
The figure shows the position of the motor

connector block when axis 2 is in position
0°.
5 If the gear is refitted in a hanging lower Screws: 3HAB3409-239 ( M4x35).

• Person 2: Refit the drive unit screws.
xx1300002554
Note

6 If the drive unit is refitted in a hanging lower Tightening torque: 5 Nm

• Person 2: Tighten the screws.

4 Repair
Continued
Action Note
Note

Action Note
Replace if damaged.
xx1300002556

Note

xx1400001403

4 Repair
Continued
Action Note
3HAC049704-001
xx1300002562

(option 287-10)
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

Room robots.
xx1400000453

xx1300002563

4 Repair
Continued
Action Note
xx1300002564
Note


quid Loctite 243.
xx1300002565

4 Repair
Continued
Action Note
(option 287-10)
Plus (option 287-3)
Room
Replace if damaged.
xx1400000007

type Clean Room)
xx1300002551

4 Repair
Continued
Action Note
Replace if damaged.
xx1600001151

Room
smooth joint.
cover joint.
xx1600000217

Plus (option 287-3)
xx1600001154

Note


4 Repair
Continued
Securing the cabling to the swing
Action Note
2 Refit the cable housing to the swing with Tightening torque: 3 Nm.
the screws.
xx1300002549
3 Insert the cable harness into the lower arm.
xx1300002548

4 Repair
Continued
Action Note
• R2.ME2
• R2.MP2
xx1300002434
5 Refit the axis-2 motor bracket with the

screws.
xx1300002432
6 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

4 Repair
Continued
Action Note
(option 287-10) 3HAC056726-001
Plus (option 287-3)
Room
cover.
Replace if damaged.

surface.
10 Refit the cable housing cover with the Cable housing cover of the swing:
screws. 3HAC059678-001
Note type Clean Room)
Cable housing cover of the swing, Clean
Remember to refit the two lower screws Room
shown in the figure. Cable housing cover of the swing, food
grade lubrication
Screws: 3HAB3409-207 (M3x8).
xx1300002431
Note


4 Repair
Continued
Action Note
11 For robots with with protection type Clean Swing sealing plug:3HAC053687-001
Room
Follow the procedure specified in Refitting
the swing sealing plug on page 151.
xx1600000205

Note

Action Note
1 Remove the lifting slings from the robot.
on page 737.
3
CAUTION

Note

free cloth.
4
DANGER

page 28.

4 Repair
Location of drive unit

The axis-3 drive unit is located as shown in the figure.
xx1300002527
Note

Drive unit 3HAC061403-001 Includes axis-3 gearbox, AC
(3HAC048939-002).

4 Repair
Continued

Drive unit, food grade lubrication 3HAC057905-001 Used for robots with food grade
lubrication.
(3HAC048939-002).
Drive unit, SafeMove 2-suppor- 3HAC061275-001 Used for IRB 1200 Type B. See
ted Type B of IRB 1200 on page 798.
(3HAC048939-002).
Drive unit, food grade lubrication 3HAC061276-001 Used for IRB 1200 Type B. See
and SafeMove 2-supported. Type B of IRB 1200 on page 798.
lubrication.
(3HAC048939-002).
Foundry Plus.
Replace if damaged.
Foundry Plus.
Replace if damaged.
IP40.
Replace if damaged.
Gasket on lower arm cover 3HAC056725-001 Not used with protection class
IP40.
Replace if damaged.
housing IP40.
Replace if damaged.
IP40.
Replace if damaged.

Guide pin for upper arm 3HAC049705-001 Always use three guide pins together!

4 Repair
Continued

method. i
Cleaning agent - Isopropanol
Clean Room
Harmonic grease 4B No. 2 3HAC037302-001 Total amount: 32 g.
Used to lubricate the gearbox.
tion.
LUBRIPLATE SYNXTREME FG-0 3HAC043771-001 Total amount: 32 g.
Used to lubricate the gearbox of
robots with food grade lubrica-
tion.
tion.

Action Note

4 Repair
Continued
Action Note
calibration:

Use these procedures to remove the axis-3 drive unit.
Preparations before removing the axis-3 drive unit

Action Note
procedure.
xx1300002581
3
DANGER
Turn off all:

area.

4 Repair
Continued
Action Note
4
CAUTION

parts on page 144.
xx1300002400
6 Remove the plate.
xx1300002413

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
CAUTION

parts on page 144.
xx1300002420
Creating space for separation of upper and lower arm
Action Note
1
DANGER

are turned off.
2
CAUTION

3 Remove the screws that fasten the fix sheet

to the inner plastic guide.
xx1300002421

4 Repair
Continued
Action Note
4 Remove the screws that fasten the fix sheet
to the motor.
xx1300002423
5 Pull out the cable harness slightly from the

upper arm housing and from the lower arm.
Note
The cabling is still connected inside the

robot, so be careful not to strain the cables!
xx1300002530

by removing the screws, and tilt it out-
wards.
xx1400000785

4 Repair
Continued
Removing the upper arm
Action Note
1
DANGER

are turned off.
2
CAUTION

3 Remove the lower arm cover.
xx1300002528
4
CAUTION
The upper arm weighs 17 kg.

accordingly!
5 Fit lifting slings to the upper arm to support

the weight of the arm. (no force)

4 Repair
Continued
Action Note
6 Remove the upper arm screws.
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
7 Fit guide pins to the upper arm. Guide pin for upper arm: 3HAC049705-001
xx1400000771
8 Separate the upper and lower arm with

guidance from the guide pins.
xx1300002533

4 Repair
Continued

Action Note
1
CAUTION

parts on page 144.
2 Remove the drive unit screws.
xx1300002532
CAUTION
The axis-3 gear unit and motor adapter are not

secured to each other with screws! Be careful
when handling the drive unit.
xx1300002534

Use this procedure to refit the axis-3 drive unit.
Action Note
grade lubrication).

4 Repair
Continued
Action Note
3 Check the o-ring for damage. Replace if O-ring: 3HAC048939-002
damaged.
xx1400000004
4 Remove the two screws and nuts that se-

cure the axis-3 motor adapter and gear unit
to each other during transport.
(option 287-10)
Plus (option 287-3)
mounting surfaces of the motor adapter.
Note

overflowing Loctite 574 if there is any. xx1400000784
6 Refit the drive unit into the upper arm.
Note
Make sure to refit the drive unit correctly

oriented. When the upper arm is in its zero
position (horizontal), the motor connectors
should point downwards.
xx1300002534

4 Repair
Continued
Action Note
7 Refit the drive unit screws. Screws: 3HAB3409-214 (M4x40)
xx1300002532
Note


Note

Refitting the upper arm
Action Note
2 Fit guide pins to the axis-3 gear unit. Guide pin for upper arm: 3HAC049705-001
xx1400000027

4 Repair
Continued
Action Note
(option 287-10)
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

Room robots.
xx1400000474
4 Refit the upper arm to the lower arm and Screws: 3HAB3409-213 (M4x25).
secure with the upper arm screws and
washers. Do not tighten yet.
xx1400000028
Note


4 Repair
Continued
Action Note
ing screws and washers.
xx1400000029
6 Tighten all screws. Tightening torque: 4.5 Nm.

7 For robots with protection class IP67 Gasket on lower arm cover: 3HAC056725-
(option 287-10) 001
Plus (option 287-3)
Room
Check the lower arm cover gasket.
Replace if damaged.
xx1400000047

4 Repair
Continued
Action Note
8 Refit the lower arm cover. Screws: 3HAB3409-207 (M3x8).
xx1300002528
Note

(option 287-10) 3HAC044895-001
Plus (option 287-3)
Room
Replace if damaged.
xx1400000414

4 Repair
Continued
Action Note
(option 287-10) Radial sealing: 3HAC024865-001
Plus (option 287-3)
Room
Check the axis-3 radial sealing and the M2
variseal sealing in the cable housing.
Replace if damaged.
Note

Note

placement. Replacement is detailed in Replacing the
axis-3 radial sealing and sealing ring on
CAUTION page 379.

Room robots.
11 Refit the cable housing of the lower arm. Tightening torque: 3 Nm
xx1400000785

4 Repair
Continued
Action Note
Room
arm.
smooth joint.
cover joint.
Note xx1600000218

in the figure.

Plus (option 287-3)
xx1600001155

Note


4 Repair
Continued
Action Note
xx1300002423
xx1300002421
xx1300002420

4 Repair
Continued
Action Note
xx1300002413
(option 287-10) 3HAC056724-001
Plus (option 287-3)
Room
cover.
Replace if damaged.
xx1400000048

4 Repair
Continued
Action Note
cover. 3HAC044660-001
Replace if damaged.
surface.
xx1300002400
Note

9
CAUTION

.
Note

free cloth.

on page 737.

4 Repair
Continued
Action Note
11
DANGER

page 28.

4 Repair
4.6.4 Replacing the axis-4 gearbox, drive shaft and pulley
Location of gearbox, drive shaft and pulley

The axis-4 gearbox, including drive shaft and pulley, is located as shown in the
figure.
xx1300002462
Note

Gearbox 3HAC049629-001
Gearbox, food grade lubrication 3HAC057904-001 Used for robots with food grade
lubrication.
Shaft 3HAC044692-001
Pulley 3HAC044687-001
Gearbox sleeve 3HAC044685-001
Foundry Plus.
Replace if damaged.

4 Repair
Continued

IP40.
Replace if damaged.
IP40.
Replace if damaged.
IP40.
Replace if damaged.
cover IP40.
Replace if damaged.
1200-7/0.7 ) IP40.
Replace if damaged.
1200-5/0.9 ) IP40.
Replace if damaged.

method. i
Cable straps -

4 Repair
Continued

Clean Room

Action Note
calibration:
Removing the gear unit

Preparations before removing the axis-4 gear unit
Action Note
procedure.

4 Repair
Continued
Action Note
xx1300002581
3
DANGER
Turn off all:

area.

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note

287-10)
(option 287-3)
locking liquid.
figure.
xx1300002349
Note
Clean Room
figure.
xx1600001148

Action Note
1
DANGER

off.

• R3.MP5
• R3.ME5
Tip

CAUTION

parts on page 144.

4 Repair
Continued
Action Note
1
DANGER

are turned off.
2
CAUTION


be moved sideways.
xx1300002350
xx1300002351

connectors.
xx1300002390

4 Repair
Continued
Action Note
xx1300002352
Removing the wrist

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
xx1300002353
xx1300002355

4 Repair
Continued
Action Note
xx1300002356

move the plate.
xx1300002357

xx1300002358

4 Repair
Continued
Action Note
wrist.
connectors.

xx1300002611

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
CAUTION

xx1300000456

4 Repair
Continued
Action Note
xx1300002494
Tip

when reconnecting.
xx1300002495

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
xx1300002400
4 Remove the plate.
xx1300002413

4 Repair
Continued
Action Note
disconnect them.
xx1300002412
xx1400001471
xx1300002398

4 Repair
Continued
Action Note
xx1300002399
Removing the axis-4 motor
Action Note
1
DANGER

are turned off.
2
CAUTION

3 Loosen the two attachment screws and

move the motor downwards to slacken the
timing belt.
xx1300002524

4 Repair
Continued
Action Note
4 Remove the motor screws and washers
and carefully lift out the motor and the pul-
ley.
xx1300002522
5 Remove the timing belt from its groove on

the motor.
Removing the air hoses
Action Note
1
DANGER

are turned off.
2
3 Remove the plastic protection plate by re-
moving its screws.
xx1400000797
4 Pull in the air hoses into the housing, out

from the housing extender unit.

4 Repair
Continued

Action Note
1
CAUTION

parts on page 144.
xx1300002373

xx1600000262
xx1300002372

xx1300002374

4 Repair
Continued
Removing the axis-4 drive shaft
Action Note
1
DANGER

are turned off.
2
xx1300002376
4 Remove the shaft.
xx1400002400
5 If replacing the drive shaft with a new spare

part, remove the sleeve from the shaft and
fit it to the new shaft.
xx1300002387

4 Repair
Continued
Removing the axis-4 gear unit and pulley
Action Note
1
DANGER

are turned off.
2
3 Remove the gear attachment screws.
xx1300002378
4 Pull out the gear.
xx1300002379

4 Repair
Continued
Action Note
5 Remove the pulley from the gear by remov-
ing its attachment screws.
xx1300002380
Refitting the gear unit

Refitting the axis-4 gear unit and pulley
Action Note
2 Refit the pulley to the gear and secure with Screws: 3HAB3409-209 (M3x20).
its attachment screws. Tightening torque: 1.1 Nm.
xx1300002380
Note


4 Repair
Continued
Action Note
3 Refit the gear to the housing.
xx1300002379
4 Secure with the attachment screws. Screws: 3HAB3409-211 (M3x30).

xx1300002378
Note


Note


4 Repair
Continued
Refitting the axis-4 drive shaft
Action Note
2 If replacing the drive shaft with a new spare Screws: 3HAB3409-207 (M3x8).
part, remove the sleeve from the old shaft Tightening torque: 1.5 Nm.
and fit it to the new shaft.
Also move the screw on top of the old drive
shaft to the new shaft.
xx1300002387
3 Position the shaft so that the encircled

screw is on top, then refit the shaft.
xx1300002377
4 Secure with screws and washers. Screws: 3HAB3409-210 (M3x25).

xx1300002376
Note


4 Repair
Continued
Action Note
Note

Action Note
(option 287-10)
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

Room robots.
xx1300002418

4 Repair
Continued
Action Note
(option 287-10)
Plus (option 287-3)
Room
xx1400000438

tender unit.
M6X50.
xx1400000436

4 Repair
Continued
Action Note
xx1400000437

properly fitted.
unit.
Note


Action Note
parts on page 144
287-10)
(option 287-3)
Note

xx1300002613

4 Repair
Continued
Action Note
xx1600000216

CAUTION

xx1300002374
Note

the housing.

xx1300002372
(option 287-3) 001
xx1600000263

4 Repair
Continued
Action Note
xx1300002373

Note

Refitting the axis-4 timing belt and the air hoses
Action Note
1
DANGER

are turned off.

3 Place the timing belt at the gear pulley and
run the air hoses through the belt.
4 Install the air hoses in and through the
housing extender unit.
5 Refit the plastic protection plate with its
screws.
xx1400000797

4 Repair
Continued
Action Note
Note

Securing the axis-4 motor
Action Note
2 Check that:
• all assembly surfaces are clean and
undamaged.
3 Fit the timing belt to the motor pulley.

4 Repair
Continued
Action Note
4 Place the motor at its mounting position Screws: 3HAB3409-14 (M5x16).
and fasten the attachment screws and
washers just enough to still be able to
move the motor.
Position the robot with the connectors dir-
ected as shown in the figure.
Verify that the top surface of the axis-4
motor is parallel with the mounting flange
surface on the housing, shown in the figure,
when moving the motor.
xx1300002524
Note

xx1300002612
5 Install the timing belt to the pulleys and

verify that the belt runs correctly in the
grooves of the pulleys.
xx1300002525

4 Repair
Continued
Action Note
6 Move the motor to achieve correct belt Belt tension: F = 30 N.
tension (F = 30 N).
7 Secure the motor with its attachment Tightening torque: 6 Nm.
screws.
Note


Action Note
parts on page 144
Tip

xx1300002399

4 Repair
Continued
Action Note
Tip

xx1300002412
xx1400001471


4 Repair
Continued
Action Note
287-10)
(option 287-3)
housing.
Replace if damaged.
xx1300002398

001
lubrication
joint.
joint.
xx1600000214

4 Repair
Continued
Action Note
xx1300002413
xx1400000740

4 Repair
Continued
Action Note
287-10) 3HAC056724-001
(option 287-3) 3HAC044660-001
Replace if damaged.
xx1400000048

Replace if damaged.

4 Repair
Continued
Action Note
xx1300002400
Note


Note


Action Note
CAUTION

parts on page 144.
xx1300002371

4 Repair
Continued
Action Note
strap.
xx1300002494
Refitting the wrist

Action Note
parts on page 144
connectors.

xx1300002611

4 Repair
Continued
Action Note
xx1400000001
pc)).
xx1400000002
Note

pcs)).
xx1400000003
Note


4 Repair
Continued
Action Note
plate.
xx1300002356
CAUTION

xx1300002355

• R3.Eth
• R3.CPCS
xx1300002353

Note


4 Repair
Continued

Action Note
1 Check that:
damages
CAUTION

parts on page 144.
xx1300002463
Note

Action Note
xx1300002351


4 Repair
Continued
Action Note
screws.
xx1300002350

Note

Action Note
CAUTION

xx1300002390

Action Note
• R3.MP5
• R3.ME5
CAUTION

parts on page 144.
xx1300002360

4 Repair
Continued
Action Note
(option 287-10)
Plus (option 287-3)
Room
Replace if damaged.
xx1400000034
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
Room
xx1300002349
xx1600001153
Note


Note


4 Repair
Continued
Action Note
1 For robots with protection class IP67 (option Housing cover gasket (IRB 1200-
287-10) 7/0.7 ): 3HAC056698-001
For robots with protection type Foundry Plus Housing cover gasket (IRB 1200-
(option 287-3) 5/0.9 ): 3HAC056697-001
Check the gasket.
Replace if damaged.
xx1400000477
xx1300000456
Note


the joint of the upper arm housing cover.
joint.
joint.
xx1600000215
4
CAUTION

parts on page 144.
Note
After all repair work, wipe the Clean Room robot

free from particles with spirit on a lint free cloth.

4 Repair
Continued
Action Note
5 Recalibrate the robot. Calibration is detailed in section
Calibration on page 737.
6
DANGER
Make sure all safety requirements are met when

performing the first test run. These are further
detailed in the section First test run may cause
injury or damage on page 28.

4 Repair
4.6.5 Replacing the axis-4 motor with pulley
Location of motor
The axis-4 motor is located as shown in the figure.
xx1300002474
Note

Motor with pulley 3HAC045827-001
Motor with pulley, SafeMove 3HAC061277-001 Used for IRB 1200 Type B. See
2-supported. Type B of IRB 1200 on page 798.
Motor flange 3HAC047479-001 Replace if damaged.

4 Repair
Continued

1200-7/0.7 ) IP40.
Replace if damaged.
1200-5/0.9 ) IP40.
Replace if damaged.

method. i
Cable straps -
Clean Room

Action Note

4 Repair
Continued
Action Note
calibration:
Removing the motor with pulley

Use these procedures to remove the motor.
Preparations before removing the axis-4 motor

Action Note
procedure.
xx1300002581
3
DANGER
Turn off all:

area.

4 Repair
Continued

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
CAUTION

xx1300000456
xx1300002494

4 Repair
Continued
Action Note
Tip

when reconnecting.
xx1300002495
Action Note
1
DANGER

are turned off.
2
CAUTION


timing belt.
xx1300002524

4 Repair
Continued
Action Note
ley.
xx1300002522

the motor.
Separating the axis-4 motor from the motor flange
Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.
3 Remove the motor flange and bracket from the

motor by removing the screws.
xx1300002523

4 Repair
Continued
Refitting the motor with pulley

Use these procedures to refit the motor.
Fitting the axis-4 motor to the motor flange
Action Note
parts on page 144
2 Refit the motor flange and bracket to the motor Motor flange: 3HAC047479-001
with the screws. Screws: 3HAB3409-14 (M5x16).
Replace the flange if damaged. Tightening torque: 6 Nm.
xx1300002523
Note


Note

Action Note
2 Check that:
undamaged.

4 Repair
Continued
Action Note
move the motor.
xx1300002524
Note

xx1300002612

xx1300002525

4 Repair
Continued
Action Note
tension (F = 30 N).
screws.
Note


Action Note
CAUTION

parts on page 144.
xx1300002371

strap.
xx1300002494

4 Repair
Continued
Action Note
(option 287-10) 3HAC056698-001
Plus (option 287-3) 3HAC056697-001
Room
Check the gasket.
Replace if damaged.
xx1400000477
xx1300000456
Note


Room
smooth joint.
cover joint.
xx1600000215

4 Repair
Continued
Action Note
4
CAUTION

.
Note

free cloth.

6
DANGER

page 28.

4 Repair
4.6.6 Replacing the axis-4 timing belt
Location of timing belt

The axis-4 timing belt is located as shown in the figure.
xx1400000036
Note

Timing belt 3HAC044694-001
IP40.
Replace if damaged.
1200-7/0.7 ) IP40.
Replace if damaged.
1200-5/0.9 ) IP40.
Replace if damaged.

4 Repair
Continued

cover IP40.
Replace if damaged.
Air connector set with Ethernet 3HAC049664-001 Includes tubular flange, air con-
hole in flange nectors and seal bolts.
Replace if damaged.
Air connector set without Ether- 3HAC049665-001 Includes tubular flange, air con-
net hole in flange nectors and seal bolts.
Replace if damaged.

Cable straps -
Clean Room

Action Note

4 Repair
Continued
Action Note
calibration:
Removing the timing belt

Use these procedures to remove the axis-4 timing belt.
Preparations before removing the axis-4 timing belt

Action Note
procedure.
xx1300002581
3
DANGER
Turn off all:

area.
4
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
5 Remove the lower arm cable housing cover.
xx1300002400
6 Remove the tubular cable housing cover.
xx1300002389
xx1400002327

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
2
CAUTION

parts on page 144.
CAUTION

xx1300000456
xx1300002494
Tip

when reconnecting.
xx1300002495

4 Repair
Continued
Action Note
1
DANGER

are turned off.
2
CAUTION


timing belt.
xx1300002524

ley.
xx1300002522

the motor.

4 Repair
Continued
Removing the air hoses
Action Note
1
DANGER

are turned off.
2
3 Remove the plastic protection plate by re-
moving its screws.
xx1400000797
4 Pull in the air hoses into the housing, out

from the housing extender unit.
Removing the axis-4 timing belt

Action Note
1
CAUTION

parts on page 144.
2 Remove the axis-4 timing belt.
Refitting the timing belt

Use these procedures to refit the axis-4 timing belt.
Refitting the axis-4 timing belt and the air hoses
Action Note
1
DANGER

are turned off.

4 Repair
Continued
Action Note
3 Place the timing belt at the gear pulley and
run the air hoses through the belt.
4 Install the air hoses in and through the
housing extender unit.
5 Refit the plastic protection plate with its
screws.
xx1400000797

Note

Action Note
2 Check that:
undamaged.

4 Repair
Continued
Action Note
move the motor.
xx1300002524
Note

xx1300002612

xx1300002525

4 Repair
Continued
Action Note
tension (F = 30 N).
screws.
Note


Action Note
CAUTION

parts on page 144.
xx1300002371

strap.
xx1300002494

4 Repair
Continued
Connecting the air hoses

Action Note
Air connector set without Ethernet
xx1400002327
2 If equipped, reconnect the CP/CS cables. On robots with protection class

For robots with protection class IP67 (option IP67
287-10) On robots with protection type
For robots with protection type Foundry Plus Foundry Plus
(option 287-3) Gasket: 3HAC058567-001
1 Check the gasket.
For robots with protection type Clean Room:
2 Apply flange sealing Loctite 574 on the
mounting surfaces of the CP/CS connector.
xx1500000251
connectors.
xx1600001152
Action Note

4 Repair
Continued
Action Note
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

xx1300002389
Note


Note


4 Repair
Continued
Action Note
(option 287-10) 3HAC056698-001
Plus (option 287-3) 3HAC056697-001
Room
Check the gasket.
Replace if damaged.
xx1400000477
xx1300000456
Note


Room
smooth joint.
cover joint.
xx1600000215

4 Repair
Continued
Action Note
(option 287-10) 3HAC056724-001
Plus (option 287-3)
Room
cover.
Replace if damaged.
xx1400000048
cover. 3HAC044660-001
Replace if damaged.
surface.

4 Repair
Continued
Action Note
7 Refit the cable housing cover. Tightening torque: 3HAB3409-207 (M3x8).
xx1300002400
Note

8
CAUTION

.
Note

free cloth.

10
DANGER

page 28.

4 Repair
Location of motor
The axis-5 motor is located as shown in the figure.
xx1300002473
Note

Motor with pulley 3HAC045978-001
Motor with pulley, SafeMove 3HAC061278-001 Used for IRB 1200 Type B. See Type
2-supported. B of IRB 1200 on page 798.
Gasket for tubular cover 3HAC058822-001 Not used with protection class IP40.
Replace if damaged.
Gasket for tubular cable 3HAC056707-001 Not used with protection class IP40.
housing cover Replace if damaged.

4 Repair
Continued

method. i

Action Note
calibration:

4 Repair
Continued
Removing the motor with pulley

Preparations before removing the axis-5 motor, pulley or shaft
Action Note
procedure.
xx1300002581
3
DANGER
Turn off all:

area.

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note

287-10)
(option 287-3)
locking liquid.
figure.
xx1300002349
Note
Clean Room
figure.
xx1600001148

Action Note
1
DANGER

off.

• R3.MP5
• R3.ME5
Tip

CAUTION

parts on page 144.

4 Repair
Continued
Action Note
1
DANGER

are turned off.
2
CAUTION


be moved sideways.
xx1300002350
xx1300002351

connectors.
xx1300002390

4 Repair
Continued
Action Note
xx1300002352
Refitting the motor with pulley

Action Note
1 Check that:
damages
CAUTION

parts on page 144.
xx1300002463
Note

Action Note

4 Repair
Continued
Action Note
xx1300002351


screws.
xx1300002350

Note

Action Note
CAUTION

xx1300002390

4 Repair
Continued

Action Note
• R3.MP5
• R3.ME5
CAUTION

parts on page 144.
xx1300002360
Action Note
(option 287-10)
Plus (option 287-3)
Room
Replace if damaged.
xx1400000034
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
Room
xx1300002349
xx1600001153
Note


Note


4 Repair
Continued
Action Note
1
CAUTION

Note

free cloth.

3
DANGER

page 28.

4 Repair
Location of the timing belt

The axis-5 timing belt is located as shown in the figure.
xx1400000032
Note

Timing belt 3HAC044657-001
IP40.
Replace if damaged.


4 Repair
Continued


Action Note
calibration:
Removing the timing belt

Use these procedures to remove the axis-5 timing belt.
Preparations before removing the timing belt
Action Note

4 Repair
Continued
Action Note
xx1300002581
3
DANGER
Turn off all:

working area.
4
CAUTION

5 Remove the left hand side wrist cover.
xx1400000033

4 Repair
Continued
Removing the axis-5 timing belt
Action Note
1
DANGER

are turned off.

be moved sideways.
xx1300002350
3
CAUTION

xx1300002351
Refitting the timing belt

Use these procedures to refit the axis-5 timing belt.
Refitting the axis-5 timing belt
Action Note

4 Repair
Continued
Action Note
xx1300002351

tension (F = 26 N).
screws.
xx1300002350

Note

Action Note
(option 287-10)
Plus (option 287-3)
Room
Check the gasket of the wrist cover.
Replace if damaged.
xx1400000034

4 Repair
Continued
Action Note
2 Refit the cover to the wrist. Screws: 3HAB3409-207 (M3x8).
(option 287-10)
Plus (option 287-3)
Apply locking liquid Loctite 243 to the two
xx1400000033
Note

3
CAUTION

Note

free cloth.

5
DANGER

page 28.

4 Repair
4.6.9 Replacing the axis-5 and axis-6 drive unit
Location of the drive unit

The drive unit of axis-5 and axis-6 is located as shown in the figure.
xx1300002467
Note
Spare part Art. no. Note

Drive unit 3HAC059696-001 Includes axis-5 gear unit and
axis-6 drive train unit.

4 Repair
Continued
Spare part Art. no. Note

Drive unit, Cean Room 3HAC059707-001 Used with protection type
Clean Room.
Includes axis-5 gear unit and
Drive unit, food grade lubrica- 3HAC057907-001 Used for robots with food
tion grade lubrication.
Drive unit, SafeMove 2-sup- 3HAC061279-001 Used for IRB 1200 Type B.
ported See Type B of IRB 1200 on
page 798.
Drive unit, Clean Room and 3HAC061280-001 Used for IRB 1200 Type B.
SafeMove 2-supported See Type B of IRB 1200 on
page 798.
Clean Room.
Drive unit, food grade lubrica- 3HAC061281-001 Used for IRB 1200 Type B.
tion See Type B of IRB 1200 on
page 798.
Used for robots with food
grade lubrication.
M2 variseal sealing 3HAC044641-008 Used with protection class
IP67.
Foundry Plus.
Replace if damaged.
IP40.
Replace if damaged.
Sleeve 3HAC044661-001 Replace if damaged.
IP40.
Replace if damaged.
Gasket for tubular cable 3HAC056707-001 Not used with protection class
housing cover IP40.
Replace if damaged.
Protection cover for axis-6 3HAC044666-001 Used with protection type
turning disk Foundry Plus.
Replace if damaged.
T40 variseal sealing 3HAC044641-012 Used with protection type
Foundry Plus.
Replace if damaged.

4 Repair
Continued

Guide pin for tilt unit (axis 5) 3HAC049706-001 Always use three guide pins together!
method. i

Action Note
calibration:

4 Repair
Continued

Use these procedures to remove the drive unit.
Preparations before removing the axis-5 and axis-6 drive unit
Action Note
xx1300002581
3
DANGER
Turn off all:

working area.

Action Note
1
DANGER

off.

4 Repair
Continued
Action Note
2
CAUTION

parts on page 144.

287-10)
(option 287-3)
locking liquid.
figure.
xx1300002349
Note
Clean Room
figure.
xx1600001148

Action Note
1
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
nectors.
xx1300002390

screws.
xx1300002391

Note

287-10)
(option 287-3)
xx1300002392

Action Note
1
CAUTION

parts on page 144.
2 Remove the sleeve screws.
xx1300002393

4 Repair
Continued
Action Note
3 Remove the sleeve by screwing in two of the
screws into the press out holes to force the sleeve
out.
xx1300002582
4 Remove the FPC unit attachment screws and pull

out the FPC unit as far as required for the axis-6
motor connectors to be accessed.
xx1300002394
5 Disconnect the axis-6 motor connectors and re-

move the FPC unit completely.
xx1300002395

Action Note
1
DANGER

off.
2
CAUTION

parts on page 144.

4 Repair
Continued
Action Note
3 Loosen the attachment screws of the axis-5 motor
so that the motor can slide sideways.
xx1300002350
4 Slide the motor sideways to release the tension

of the timing belt, and remove the timing belt.
xx1300002351
5 Support the weight of the drive unit and remove

the screws.
xx1300002469
6 Fit guide pins to the gearbox. Guide pin for tilt unit (axis 5):
3HAC049706-001
Always use three guide pins togeth-
er!
xx1400000775
7 Remove the drive unit.
xx1300002470

4 Repair
Continued

Use these procedures to refit the drive unit.
Refitting the axis-5 and axis-6 drive unit

Action Note
parts on page 144
2 For robots with protection type Foundry Plus Protection cover for axis-6 turning
(option 287-3) disk: 3HAC044666-001
Check the protection cover for turning disk and T40 variseal sealing: 3HAC044641-
T40 variseal sealing. 012
Replace if damaged.
xx1600001126
287-10) 008
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION

bots.
xx1300002493

surfaces of the drive unit.
Note

xx1400001404

4 Repair
Continued
Action Note
5 Fit guide pins to the axis-5 gearbox. Guide pin for tilt unit (axis 5):
3HAC049706-001
xx1300002568

Make sure the sealing to the tilt covers is intact
before the refitting.
xx1600000219
xx1600000220

4 Repair
Continued
Action Note
7 Refit the drive unit and secure with the screws Attachment screws: 3HAB3409-236
and washers. (M4x10).
Note
If there is glue on the screw, please clean it or

replace it with a new one.
xx1300002569
Note

8 Remove the guide pins and refit the remaining

screws and washers.
xx1300002570
9 Cross-tighten all the screws with torque 1 Nm first,

then with 2 Nm, with 4 Nm, and finally with 4.5
Nm.
Note

Action Note
1
WARNING
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.


4 Repair
Continued
Action Note
3 Reconnect the axis-6 motor connectors to
the FPC unit.
xx1300002395
4 Carefully refit the FPC unit and secure with Tightening torque: 0.3 Nm.
screws.
Note
Check that the FPC unit is at the zero pos-

ition when refitting it.
xx1300002394

(option 287-10)
Plus (option 287-3)
mounting surfaces of the sleeve.
Note

xx1300002609

4 Repair
Continued
Action Note
6 Refit the sleeve and secure with screws. Sleeve: 3HAC044661-001
xx1300002393

Note

Action Note
Replace if damaged.
CAUTION

Room robots.
xx1300002396

4 Repair
Continued
Action Note
(option 287-10)
Plus (option 287-3)
Room
xx1300002608

housing.
M6x40.
xx1400000485

4 Repair
Continued
Action Note
xx1400000486

properly fitted.
Note


Action Note
parts on page 144
287-10)
(option 287-3)
xx1300002610
Note


4 Repair
Continued
Action Note
3HAC059695-001
Room
lubrication
xx1300002392

Note

Action Note
xx1300002351


4 Repair
Continued
Action Note
screws.
xx1300002350

Note

Action Note
the M3 screws.
xx1400001401
xx1400001402

4 Repair
Continued
Action Note
Note

Action Note
CAUTION

xx1300002390
Action Note
(option 287-10)
Plus (option 287-3)
Room
Replace if damaged.
xx1400000034

4 Repair
Continued
Action Note
(option 287-10) 3HAC056707-001
Plus (option 287-3)
Room
gasket.
Replace if damaged.
xx1400000345

4 Repair
Continued
Action Note
Room
xx1300002349
xx1600001153
Note


Note


4 Repair
Continued
Action Note
1
CAUTION

Note

free cloth.

3
DANGER

page 28.

5 Calibration
5.1.1 Introduction and calibration terminology
5 Calibration
5.1 Introduction to calibration
5.1.1 Introduction and calibration terminology
Calibration information
This chapter includes general information about the recommended calibration
methods and also the detailed procedures for updating the revolution counters,
checking the calibration position etc.
Detailed instructions of how to perform Axis Calibration are given on the
FlexPendant during the calibration procedure. To prepare calibration with Axis
Calibration method, see Calibrating with Axis Calibration method on page 746.
Calibration terminology
Term Definition
Calibration method A collective term for several methods that might be
available for calibrating the ABB robot. Each method
contains calibration routines.
Synchronization position Known position of the complete robot where the
angle of each axis can be checked against visual
synchronization marks.
Calibration position Known position of the complete robot that is used
for calibration of the robot.
Standard calibration A generic term for all calibration methods that aim
to move the robot to calibration position.
Fine calibration A calibration routine that generates a new zero posi-
tion of the robot.
Reference calibration A calibration routine that in the first step generates
a reference to current zero position of the robot. The
same calibration routine can later on be used to re-
calibrate the robot back to the same position as when
the reference was stored.
This routine is more flexible compared to fine calib-
ration and is used when tools and process equipment
are installed.
Requires that a reference is created before being
used for recalibrating the robot.
Requires that the robot is dressed with the same
tools and process equipment during calibration as
during creation of the reference values.
Update revolution counter A calibration routine to make a rough calibration of
each manipulator axis.
Synchronization mark Visual marks on the robot axes. When marks are
aligned, the robot is in synchronization position.

5 Calibration
5.1.2 Calibration methods
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration Axis Calibration or
position. manual calibration i
Standard calibration data is found on the SMB
(serial measurement board) or EIB in the robot.
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at synchronization posi-
al) tion, the Absolute accuracy calibration also
compensates for:
• Mechanical tolerances in the robot
structure
• Deflection due to load
Absolute accuracy calibration focuses on pos-
itioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with absolute accuracy has
a sticker next to the identification plate of the
robot.
To regain 100% absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy!
xx0400001197

5 Calibration
Continued
Brief description of calibration methods

Axis Calibration method
Axis Calibration is a standard calibration method for calibration of IRB 1200 and
is the most accurate method for the standard calibration. It is the recommended
method in order to achieve proper performance.
The following routines are available for the Axis Calibration method:
• Fine calibration
• Update revolution counters
• Reference calibration
The calibration equipment for Axis Calibration is delivered as a toolkit.
An introduction to the calibration method is given in this manual, see Calibrating
with Axis Calibration method on page 746.
The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
Manual calibration method

With the manual calibration method, the robot's axes are positioned in specific
calibration positions using calibration tools. Under this condition, the position of
the axis to be calibrated is pre-determined. The axes must be calibrated one at a
time.
CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute
Accuracy calibration is used as a TCP calibration. The CalibWare tool guides
through the calibration process and calculates new compensation parameters.
This is further detailed in the Application manual - CalibWare Field 5.0.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after motor and transmission replacements that do not include
taking apart the robot structure, standard calibration is sufficient. Standard
calibration also supports wrist exchange.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 816.

5 Calibration
5.1.3 When to calibrate
5.1.3 When to calibrate
When to calibrate
The system must be calibrated if any of the following situations occur.
The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration
methods supplied by ABB. Calibrate the robot carefully with standard calibration,
according to information in this manual.
If the robot has absolute accuracy calibration, it is also recommended, but not
always necessary to calibrate for new absolute accuracy.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.
The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 743. This will occur when:
• The battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are
connected at the first installation.
The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot
is changed, it needs to be recalibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.

5 Calibration
5.2.1 Synchronization marks and synchronization position for axes
5.2 Synchronization marks and axis movement directions
5.2.1 Synchronization marks and synchronization position for axes
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
Synchronization marks, IRB 1200
xx1400000402

5 Calibration
5.2.2 Calibration movement directions for all axes
5.2.2 Calibration movement directions for all axes
Overview
When calibrating, the axis must consistently be run towards the calibration position
in the same direction in order to avoid position errors caused by backlash in gears
and so on. Positive directions are shown in the graphic below.
Calibration service routines will handle the calibration movements automatically
and these might be different from the positive directions shown below.
Manual movement directions
(C)
(D)
(E)
(F)
(B)
(A)
xx1300000365
Posi- Description Posi- Description

tion tion
A Axis 1 B Axis 2
C Axis 3 D Axis 4
E Axis 5 F Axis 6

5 Calibration
5.3 Updating revolution counters
Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.
Action Note
1 Select axis-by-axis motion mode.
2 Jog the manipulator to align the synchron- See Synchronization marks and synchron-
ization marks. ization position for axes on page 741.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 743.
Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).
Action
1 On the ABB menu, tap Calibration.
xx1500000942

5 Calibration
Continued
Action
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943
3 This step is valid for RobotWare 6.04 and later.

Calibration method used at factory for each axis is shown, as well as calibration
method used during last field calibration.
Tap Manual Method (Advanced).
xx1500000944

5 Calibration
Continued
Action
4 A screen is displayed, tap Rev. Counters.
en0400000771
5 Tap Update Revolution Counters....

A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
6 Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
7 A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the selected revolution counters and removes the tick from
the list of axes.
8
CAUTION
If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 791.

5 Calibration
5.4.1 Description of Axis Calibration
5.4 Calibrating with Axis Calibration method
Instructions for Axis Calibration procedure given on the FlexPendant

This manual contains a brief description of the method, additional information to
the information given on the FlexPendant, article number for the tools and images
of where to fit the calibration tools on the robot.
Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis
at the time. The robot axes are both manually and automatically moved into position,
as instructed on the FlexPendant.
Bushings are installed on each robot axis at delivery, for installation of the
calibration tools. For axis 6 calibration there is one bushing on the wrist and one
mounting hole on the tool flange.
The Axis Calibration procedure described roughly:
• A removable calibration tool is inserted by the operator into a calibration
bushing on the axis chosen for calibration, according to instructions on the
FlexPendant.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools
from ABB. Using other pins in the calibration bushings may cause severe
damage to the robot and/or personnel.
WARNING
The calibration tool must be fully inserted into the calibration bushing, until
the steel spring ring snaps into place.
• During the calibration procedure, RobotWare moves the robot axis chosen
for calibration so that the calibration tools get into contact. RobotWare records
values of the axis position and repeats the coming-in-contact procedure
several times to get an exact value of the axis position.
WARNING
Risk of pinching! The contact force for large robots can be up to 150 kg.
Keep a safe distance to the robot.

5 Calibration
Continued
• The axis position is stored in RobotWare with an active choice from the
operator.
Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the
beginning of the procedure on the FlexPendant.
Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling
or equipment fitted to the robot.
Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the
robot is dressed with tools, process cabling or other equipment.
Also choose this routine if the robot is wall mounted or suspended.
If calibrating the robot with reference calibration there must be reference values
created before repair is made to the robot, if values are not already available.
Creating new values requires possibility to move the robot. The reference values
contain positions of all axes, torque of axes and technical data about the tool
installed. A benefit with reference calibration is that the current state of the robot
is stored and not the state when the robot left the ABB factory. The reference value
will be named according to tool name, date etc.
Follow the instructions given in the reference calibration routine on the FlexPendant
to create reference values.
When reference calibration is performed, the robot is restored to the status given
by the reference values.
Note
When calibrating the robot with the reference calibration routine, the robot must
be dressed with the same tools, process cabling and any other equipment as
when the reference values were created.
Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Validation
In the mentioned routines, it is also possible to validate the calibration data.
Position of robot axes

The axis chosen for calibration is automatically run by the calibration program to
its calibration position during the calibration procedure.
In order for the axis to be able to be moved to calibration position, or in order for
getting proper access to the calibration bushing, other axes might need to be
jogged to positions different from 0 degrees. Information about which axes are
allowed to be jogged will be given on the FlexPendant. These axes are marked
with Unrestricted in the FlexPendant window.

5 Calibration
Continued
How to calibrate a suspended or wall mounted robot

The IRB 1200 is calibrated floor standing in factory, prior to shipping.
To calibrate a suspended or wall mounted robot, reference calibration must be
used. Reference values for a suspended or a wall mounted robot must be created
with the robot mounted at its working position, not standing on a floor.
To calibrate a suspended or wall mounted robot with the fine calibration routine,
the robot must first be taken down and mounted standing on the floor.

5 Calibration
5.4.2 Calibration tools for Axis Calibration
Calibration tool set

The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
The calibration tool will eventually break from fatigue after longer period of use
and then needs to be replaced. There is no risk for bad calibrations as long as the
calibration tool is in one piece.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration bushings may cause severe damage to
the robot and/or personnel.

Calibration tool box, 3HAC062326-001 Delivered as a set of calibration tools.
Axis Calibration Required if Axis Calibration is the valid calib-
ration method for the robot. i
The tool box also includes a unique calibra-
tion pin for IRB 1200 to be fitted to the tool
flange during calibration of axis 6.
Examining the calibration tool

Check prior to usage
Before using the calibration tool, make sure that the tube insert, the plastic
protection and the steel spring ring are present.
WARNING
If any part is missing or damaged, the tool must be replaced immediately.

5 Calibration
Continued
xx1500001914
A Tube insert
B Plastic protection
C Steel spring ring
Periodic check of the calibration tool

If including the calibration tool in a local periodic check system, the following
measures should be checked.
• Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on
calibration tool size).
• Straightness within 0.005 mm.
xx1500000951
A Outer diameter
Periodic check of the calibration tool for the tool flange (3HAC058238-001)
If including the tool flange calibration tool in a local periodic check system, the
following measures should be checked.
• Outer diameter within Ø5g5 mm.
• Straightness within 0.005 mm.

5 Calibration
Continued
xx1600001142
A Outer diameter

5 Calibration
5.4.3 Installation locations for the calibration tools
Location of fixed calibration items

This section shows how the robot is equipped with items for installation of
calibration tools for Axis Calibration (fixed calibration pins and/or bushings).
Installed calibration tools are not shown.
A fixed calibration pin and a bushing for the movable calibration tool are located
on each axis as follows.
If there is not enough space on an axis to install a fixed calibration pin, the axis is
equipped with two bushings instead, for installation of two calibration tools when
calibration is carried out. This is shown in the figure.
For axis 6 there is only one bushing, the second calibration tool is installed at the
mounting flange of the turning disk.
xx1600001035

5 Calibration
Continued
xx1600001036
Spare parts
When calibration is not being performed, a protective plug should always be
installed in the bushing. Replace damaged parts with new, if needed.
Protective plug for bushing 3HAC059556-001 Replace if damaged or missing.
Protective plug for bushing, Clean 3HAC059557-001 Replace if damaged or missing.
Room
Protective plug for bushing, food
grade lubrication

5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Required tools
The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration holes may cause severe damage to the
robot and/or personnel.

Calibration tool box, Axis 3HAC062326-001 Delivered as a set of calibration tools.
Calibration Required if Axis Calibration is the valid
calibration method for the robot. i
The tool box also includes a unique
calibration pin for IRB 1200 to be fitted
to the tool flange during calibration of
axis 6.
Consumable Article number Note
Clean cloth -
Spare parts

Protective plug for bushing 3HAC059556-001 Replace if damaged or missing.
Protective plug for bushing, Clean 3HAC059557-001 Replace if damaged or missing.
Room
grade lubrication
Overview of the calibration procedure on the FlexPendant

Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure sequence.

5 Calibration
Continued
After the calibration method has been called for on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine. The routines are described in Routines in the
calibration procedure on page 747.
2 Choose which axis/axes to calibrate.
3 The robot moves to synchronization position.
4 Validate the synchronization marks.
5 The robot moves to preparation position.
6 Remove the protection plug from the bushings, and install the calibration
tool.
7 The robot performs a measurement sequence by rotating the axis back and
forth.
8 Remove the calibration tool and reinstall the protection plugs in the bushings.
9 The robot moves to verify that the calibration tool is removed.
10 Choose whether to save the calibration data or not.
Calibration of the robot is not finished until the calibration data is saved, as last
step of the calibration procedure.
Preparation prior to calibration

The calibration procedure is described in the FlexPendant while conducting it.
Action Note
1
DANGER
While conducting the calibration, the robot needs

to be connected to power.
Make sure that the robots working area is empty,
as the robot can make unpredictable movements.
2 Wipe the calibration tool clean. Use a clean cloth.
Note
The calibration method is exact. Dust, dirt or color

flakes will affect the calibration value.

5 Calibration
Continued
Starting the calibration procedure

Use this procedure to call for the Axis Calibration method on the FlexPendant.
Action Note
1 On the ABB menu, tap Calibration.
xx1500000942
2 All mechanical units connected to the system are

shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943

5 Calibration
Continued
Action Note
3 Calibration method used at factory for each axis The FlexPendant will give all inform-
is shown, as well as calibration method used for ation needed to proceed with Axis
the robot during last field calibration. Calibration.
Tap Run Calibration Method. The software will
automatically call for the procedure for the valid
calibration method.
xx1500000944
4 Follow the instructions given on the FlexPendant. A brief overview of the sequence
that will be run on the FlexPendant
is given in Overview of the calibra-
tion procedure on the FlexPendant
on page 754.
Fitting of calibration tools

The figures show the calibration tools in contact with each other on each axis.
The position of the complete robot shown for each axis is only an example.
In order for the axis to be able to be moved to calibration position, or in order for
getting proper access to the calibration bushing, other axes might need to be
jogged to positions different from 0 degrees. Information about which axes are
allowed to be jogged will be given on the FlexPendant. These axes are marked
with Unrestricted in the FlexPendant window.
Calibration tools in contact
Axis 1 Axis 2
xx1600001277 xx1600001276

5 Calibration
Continued
Calibration tools in contact

Axis 3 Axis 4
xx1600001275 xx1600001274
Axis 5 Axis 6
Make sure to orient the tool flange calibration
tool correctly.
xx1600001273
xx1600001272
Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished,
the RobotWare program needs to be started again. Use this procedure to take
required action.
Situation Action
The three-position enabling device on the Press and hold the three-position enabling
FlexPendant has been released during robot device and press Play.
movement.

5 Calibration
Continued
Situation Action
The RobotWare program is terminated with Remove the calibration tool, if it is installed,
PP to Main. and restart the calibration procedure from
the beginning. See Starting the calibration
procedure on page 756.
If the calibration tool is in contact the robot
axis needs to be jogged in order to release
the calibration tool. Jogging the axis in wrong
direction will cause the calibration tool to
break. Directions of axis movement is shown
in Calibration movement directions for all
axes on page 742
Axis Calibration with SafeMove option

To be able to run Axis Calibration SafeMove needs to be unsynchronized. The Axis
Calibration routine recognizes if the robot is equipped with SafeMove and will force
SafeMove to unsynchronize automatically.
However, SafeMove may generate other warning messages anytime during the
Axis Calibration routine.
Safety controller not synchronized - SafeMove message
Action Note
1 SafeMove generates the message "Safety control-
ler not synchronized".
xx1500002480
2 Confirm unsynchronized state by pressing Ac-

knowledge to continue Axis Calibration proced-
ure.
3 Restart Axis Calibration procedure by pressing
Play.

5 Calibration
Continued
Unsynchronized speed exceeded - SafeMove message while saving robot data
Action Note
1 SafeMove generates the message "Unsynchron-
ized speed exceeded" while saving robot data.
xx1500002481
2 Press Acknowledge to continue Axis Calibration

procedure.
Play.
Unsynchronized time limit expired - SafeMove message anytime during Axis Calibration routine
Action Note
1 SafeMove generates the message "Unsynchron-
ized time limit expired" (anytime).
xx1500002482
2 Press OK to continue Axis Calibration procedure.

Play.

5 Calibration
Continued
After calibration
Action Note
1 Check the o-ring on the plug.
Replace the plug with new spare part, if missing
or damaged.
xx1600001143
Protective plug for bushing:

3HAC059556-001.
: 3HAC059557-001.
Protective plug for bushing, Clean
Room
grade lubrication
2 Reinstall the protective plugs in both bushings on
each axis, directly after the axis is calibrated.
Replace the plug with new spare part, if missing
or damaged.
xx1600001144

5 Calibration
5.5.1 Manual calibration method - calibration position
5.5 Calibrating with manual calibration method
5.5.1 Manual calibration method - calibration position
Calibration position
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
1 +84.474066º +84.474066º
2 +131.862755º +136.862755º
3 +72.250000º +72.250000º
4 0º 0º
5 -90º -90º
6 0º 0º

5 Calibration
5.5.2 Manual calibration method - content of calibration toolkit 3HAC051256-001
5.5.2 Manual calibration method - content of calibration toolkit 3HAC051256-001
Content of calibration toolkit 3HAC051256-001

Content in calibration toolkit Art. no. Note
3HAC051256-001
Calibration pin, axis 1 3HAC051209-001
Calibration stop pin, axis 1 3HAC051211-001
Calibration tool, axis 4 3HAC051212-001
Calibration tool, axes 5 and 6 3HAC051213-001
Conical screw M3 3HAC055410-001 Used together with the calibration
tool, axis 4.
Guide pin 3HAC034513-001 Used together with the calibration
tool, axis 5/6.
Calibration block with pin 3HAC051254-001 Fitted on tubular.
Hex socket head screw 9ADA183-19 M5x40

5 Calibration
5.5.3 Manual calibration method - calibrating axis 1
Calibration position of axis 1

The figure shows axis 1 in calibration position, with calibration tools fitted.
xx1400001209
Required equipment
Calibration toolkit, manual calibra- 3HAC051256-001 Includes calibration tools, pins
tion and attachment screws for
manual calibration method. i

5 Calibration
Continued

Protection plug 3HAC051199-001 Protection plug for the calibration
hole in the swing (the hole is used
during calibration of axis 1 with
the manual calibration method).
Replace if damaged.
Calibrating axis 1
Moving the robot to calibration position
Action Note
2 Remove the axis-1 mechanical stop pin.
xx1400000392

5 Calibration
Continued
Action Note
3 The axis-1 calibration stop pin should now be fit- Screw: M8x45.
ted to the mechanical stop pin attachment hole, Tightening torque: 10 Nm.
but it does not fit if the axis 1 stands in its zero
position.
Note
Jog axis 1 to find a suitable position where the
axis-1 calibration stop pin can be fitted to the at- The position of the robot shown in
tachment hole in the base. the figure, is only a suggestion.
Fit the axis-1 calibration stop pin to the base and The suitable position in which the
secure it with the screw. axis-1 calibration pin is possible to
fit may differ.
xx1400001100
4 Jog axis 1 to zero position.

5
DANGER
Turn off all:

area.
6 Remove the protection plug from the swing.
xx1400001134

5 Calibration
Continued
Action Note
7 Fit the axis-1 calibration pin to the swing and se- Screw: M5x40.
cure it with the screw. TighteningTorque: 5 Nm.
CAUTION
Hold the calibration pin firmly with your hands

while securing it with the screw, in order to keep
a straight line when fitting the screw. The calibra-
tion pin must not be tilted.
xx1400001099
8 Turn on the electric power to the robot.

9
DANGER

may move very quickly and sometimes in unex-
pected ways!
robot arm!
10 Release the brakes and manually rotate axis 1 How to release the brakes is de-
until the two axis-1 calibration pins touches each tailed in Manually releasing the
other gently. There should be no pressing force brakes on page 74.
between the pins.
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

5 Calibration
Continued
Performing the fine calibration procedure

Action Note
1
WARNING
Do not fine calibrate the robot without special

equipment used for axis calibration! It would
cause an unsatisfied accuracy in the robot
movement.
2 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.
3 Tap to select the mechanical unit and then tap Calib. Parameters.
en0400001127
4 Tap Fine Calibration....

A dialog box is displayed, urging you to use ex-
ternal equipment to perform the actual calibration.
Make sure all necessary calibration equipment is
fitted for the axis to be calibrated.
A dialog box is displayed, warning that updating
the revolution counters may change programmed
robot positions:
• Tap Yes to proceed.
• Tap No to cancel.
5 Select the check-box for the current axis/axes to
be calibrated.

5 Calibration
Continued
Action Note
6 Tap Calibrate.
A dialog box is displayed, warning that calibration
of the selected axes will be changed, which cannot
be undone:
• Tap Calibrate to proceed.
• Tap Cancel to cancel.
Tapping Calibrate results in briefly displaying a
dialog box, announcing that the calibration pro-
cess has started.
The axis is calibrated and the system returns to
the list of available mechanical units.
Checking and finalizing the calibration

Action Note
1 Release the brakes and manually rotate the axis
to apart the calibration pins from each other. This
is done to avoid damage on the pins if incorrect
operation should occur during next step of jog-
ging.
2 Jog axis 1 to zero degree using the FlexPendant.
3 Check that the synchronization marks on axis 1
are aligned with eachother.
Are they aligned within the tolerances?
• If yes, the calibration is verified OK.
• If no, redo the fine calibration procedure.
xx1400001092
4 Remove the axis-1 calibration pin from the swing Protection plug: 3HAC051199-001
and refit the protection plug.
xx1400001134
5 Rotate axis 1 to a suitable position to get access

and remove the calibration stop pin from the base.
6 Remove the axis-1 calibration stop pin from the Tightening torque: 12 Nm
base and refit the axis-1 mechanical stop.
xx1400000392

5 Calibration
Continued
After calibration
Action Note
1 Write down the new system parameters on a new
label and stick on top of the calibration label on
the robot.

5 Calibration

The figure shows axis 2 in calibration position.
xx1400001201
Required equipment
Calibration of axis 2 is done by moving the lower 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.
See figures below for reference, and follow the step-by-step procedure that follows.
Calibration pin Calibration stop
xx1400001136
xx1400001135
The press fit mechanical stop pin fitted to the The axis-2 mechanical stop fitted to the
lower arm is used for calibration of axis 2. swing is used for calibration of axis 2.
No additional equipment is required. No additional equipment is required.

5 Calibration
Continued
Calibrating axis 2
Action Note
2
DANGER

pected ways!
robot arm!
until the axis-2 calibration pin and calibration stop tailed in Manually releasing the
touches each other gently. There should be no brakes on page 74.
pressing force between the pins. The calibration pin and calibration
When doing this, pay attention to robot pose in stop are illustrated in Required
order to avoid arm collision. equipment on page 771.
xx1400001201

Action Note
1
WARNING

movement.


5 Calibration
Continued
Action Note
en0400001127

robot positions:
be calibrated.
6 Tap Calibrate.
be undone:
cess has started.

Action Note
ging.

5 Calibration
Continued
Action Note
xx1400001093
After calibration
Action Note
the robot.

5 Calibration

The figure shows axis 3 in calibration position.
xx1400001204
Required equipment
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.

5 Calibration
Continued
See figures below for reference, and follow the step-by-step procedure that follows
the figures.
Calibration pin Calibration stop
xx1400001202 xx1400001203
The press fit mechanical stop pin fitted to the The axis-3 mechanical stop fitted to the lower
upper arm is used for calibration of axis 3. arm is used for calibration of axis 3.
No additional equipment is required. No additional equipment is required.
Calibrating axis 3
Action Note
2
DANGER

pected ways!
robot arm!

5 Calibration
Continued
Action Note
until the axis-3 calibration calibration pin and cal- tailed in Manually releasing the
ibration stop touches each other gently. There brakes on page 74.
should be no pressing force between the pins. The calibration pin and calibration
When doing this, pay attention to robot pose in stop are illustrated in Required
order to avoid arm collision. equipment on page 775.
xx1400001204

Action Note
1
WARNING

movement.


5 Calibration
Continued
Action Note
en0400001127

robot positions:
be calibrated.
6 Tap Calibrate.
be undone:
cess has started.

Action Note
ging.

5 Calibration
Continued
Action Note
xx1400001094
After calibration
Action Note
the robot.

5 Calibration

The figure shows axis 4 in calibration position, with calibration tools fitted.
xx1400001207
Required equipment
Calibrating axis 4
Action Note
Rotate axis 4 some degrees toward positive direc-
tion to avoid interference between the calibration
tools when fitting them.

5 Calibration
Continued
Action Note
2
DANGER
Turn off all:

area.
3 Remove the protection cover from the housing.
xx1400001205
4 Clean the location surfaces on the housing and

the calibration tool surfaces to make sure there
is no paint or burrs on these surfaces.
5 Fit the calibration block to the tubular. Screws: M4x16.
xx1400001208
6 Locate the calibration tool by the location surface

on the housing.
Tip
Press down slightly on the calibration tool to make

sure the tool attaches the location surface tightly.

5 Calibration
Continued
Action Note
7 Fit the conical screw to the calibration tool. Conical screw M3 (3HAC055410-
001, 1 pcs)
xx1500001608
8 Fit the M5 screws. Screws: M5x20.

xx1400001117
9 Turn on the electric power to the robot.

10
DANGER

pected ways!
robot arm!
until the axis-4 calibration tool and the calibration tailed in Manually releasing the
block touches each other gently. There should be brakes on page 74.
no pressing force between the pins.
xx1400001207

5 Calibration
Continued

Action Note
1
WARNING

movement.

en0400001127

robot positions:
be calibrated.

5 Calibration
Continued
Action Note
6 Tap Calibrate.
be undone:
cess has started.

Action Note
ging.
2 Remove the calibration tool of axes 4, 5, and 6
from the tubular.
3 Remove the axis-4 calibration tool from the
housing.
xx1400001095
6 Refit the protection cover to the housing.
xx1400001205

5 Calibration
Continued
After calibration
Action Note
the robot.

5 Calibration
5.5.7 Manual calibration method - calibrating axis 5 and axis 6
Calibration position of axes 5 and 6

The figure shows axes 5 and 6 in calibration position, with calibration tools fitted.
xx1400001206
Required equipment
Calibrating axis 5 and axis 6

Action Note
2
DANGER
Turn off all:

area.

5 Calibration
Continued
Action Note
3 Fit the calibration block to the tubular. Screws: M4x16.
xx1400001114
4 Fit the guide pin to the disk and then fit the calib- Screws: M5x16.
ration tool of axes 5 and 6.
xx1400001115
5
DANGER

pected ways!
robot arm!
6 Release the brakes and manually rotate axes 5 How to release the brakes is de-
and 6 until the axis-5/6 calibration tool and the tailed in Manually releasing the
calibration block touches each other gently. There brakes on page 74.
should be no pressing force between the pins.
xx1400001206

5 Calibration
Continued

Action Note
1
WARNING

movement.

en0400001127

robot positions:
be calibrated.

5 Calibration
Continued
Action Note
6 Tap Calibrate.
be undone:
cess has started.

Action Note
ging.
2 Jog axis 5 and 6 to zero degree using the Flex-
Pendant.
and axis 6 are aligned with eachother.
xx1400001096
xx1400001097
4 Remove the calibration block from the tubular.

5 Remove the calibration tool of axes 5 and 6 from
the disk.
After calibration
Action Note
the robot.

5 Calibration
5.6 Verifying the calibration
5.6 Verifying the calibration
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
Verifying the calibration

Use this procedure to verify the calibration result.
Action Note
1 Run the calibration home position program twice. See Checking the synchron-
Do not change the position of the robot axes after running ization position on page 791.
the program!
2 Adjust the synchronization marks when the calibration is This is detailed in section
done, if necessary. Synchronization marks and
synchronization position for
axes on page 741.
3 Write down the values on a new label and stick it on top
of the calibration label.
The label is located on one side of the base.
4 Remove any calibration equipment from the robot.

5 Calibration
5.7 Checking the synchronization position
5.7 Checking the synchronization position
Introduction
Check the synchronization position of the robot before beginning any programming
of the robot system. This may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the FlexPendant.
Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 On ABB menu tap Program editor.
2 Create a new program.
3 Use MoveAbsJ in the Motion&Proc menu.
4 Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0
5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 741 and Updating revolution
counters on page 743.
Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 On the ABB menu, tap Jogging.
2 Tap Motion mode to select group of axes
to jog.
3 Tap to select the axis to jog, axis 1, 2, or
3.
4 Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
5 Check that the synchronization marks for See Synchronization marks and synchron-
the axes align correctly. If they do not, up- ization position for axes on page 741 and
date the revolution counters. Updating revolution counters on page 743.

6 Decommissioning
6.1 Introduction
6 Decommissioning
6.1 Introduction
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
General
All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. 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.

6 Decommissioning
6.2 Environmental information
6.2 Environmental information
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Batteries, NiCad or Lithium Encoder interface board
Copper Cables, motors
Cast iron/nodular iron Gears
Steel Gears, screws, washers, brackets
Stainless steel Mechanical stop
Neodymium Motors
Oil, grease Gears
Aluminium Base, lower arm, upper arm
Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.
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.

6 Decommissioning
6.3 Scrapping of robot
6.3 Scrapping of robot
Important when scrapping the robot
DANGER
When a robot is disassembled while being scrapped, it is very important to

remember the following before disassembling starts, in order to prevent injuries:
• Always remove all batteries. If a battery is exposed to heat, for example
from a blow torch, it will explode.
• Always remove all oil/grease in gearboxes. If exposed to heat, for example
from a blow torch, the oil/grease will catch fire.
• When motors are removed from the robot, the robot will collapse if it is not
properly supported before the motor is removed.

7 Robot description
7.1 Type A of IRB 1200
7 Robot description
7.1 Type A of IRB 1200
Type A - Axis Calibration

The difference between IRB 1200 and IRB 1200 Type A is that the Type A is
calibrated with Axis Calibration. On each axis there are bushings for installation
of calibration tools.
As a result of this, the castings differ between IRB 1200 and IRB 1200 Type A.
Note
IRB 1200 Type B is designed based on IRB 1200 Type A so that Type B has the
bushings for installation of calibration tools too.
The difference between IRB 1200 Type A and IRB 1200 Type B is that Type B
also supports SafeMove 2. See Type B of IRB 1200 on page 798.
How to know which type the robot is?

The type label on the base of the robot tells if the robot is calibrated with Axis
Calibration.
Those robots are named IRB 1200 Type A.
Note
If no type label attached on the robot, use the bushings on each axis to identify
a robot calibrated with Axis Calibration.
Those robots which are not equipped for Axis Calibration are simply named IRB
1200 (no type specified).

7 Robot description
7.2 Type B of IRB 1200
7.2 Type B of IRB 1200
Type B - SafeMove 2
The difference between IRB 1200 Type B and other IRB 1200 versions is that the
Type B supports SafeMove 2.
As a result of this, the following parts differ from other versions:
• Base
• Drive unit, axis 2, axis 3, axis 5 and axis 6
• Motor with pulley, axis 4 and axis 5
• Manipulator cable harness
• Battery pack
• SMB unit (replacing EIB unit)
IRB 1200 Type B is designed based on IRB 1200 Type A so that Type B has the
bushings for installation of calibration tools too.
How to know which type the robot is?

The type label on the base of the robot tells if the robot supports SafeMove 2.
Those robots are named IRB 1200 Type B.

7 Robot description
7.3.1 Spare part versions for the base on IP40/IP67 robots
7.3 Description of spare part versions
Spare part versions for the base on IP40/IP67 robots
Note
IRB 1200 has different base versions that are not compatible with each other.
Always use the following list as a reference to check the base installed on robot
and order the correct spare parts.
Base installed on ro- Article number in What to order How to see which version is installed
bot (spare part num- WebConfig on robot
ber)
3HAC049628-001 3HAC044533-001 Order: Look on the outside of the base.
• base 3HAC059553-001 Base 3HAC049628-001 has no hole on
• swing 3HAC059554-001 the side of the base.
• IP40: sealing ring
3HAC058568-001
• IP67: sealing ring + gasket
+ V-ring 3HAC058001-001
xx1600000124
3HAC057999-001 3HAC056657-001 Order: Base 3HAC057999-001 has a hole on

• base 3HAC059553-001 the side of the base.
xx1600000051

7 Robot description
Continued
Base installed on ro- Article number in What to order How to see which version is installed
bot (spare part num- WebConfig on robot
ber)
3HAC059553-001 3HAC058386-001 Order: Base 3HAC059553-001 has a bushing
• base 3HAC059553-001 for fitting calibration tool for Axis Calib-
ration.
xx1600001037

7 Robot description
7.3.2 Spare part versions for the swing on IP40/IP67 robots
Spare part versions for the swing on IP40/IP67 robots
Note
IRB 1200 has different swing versions that are not compatible with each other.
Always use the following list as a reference to check the swing installed on robot
and order the correct spare parts.
Swing installed on ro- Article number in What to order How to see which version is in-
bot (spare part num- WebConfig stalled on robot
ber)
3HAC049632-001 3HAC044534-001 Order: Look underneath the swing, the sur-
• swing 3HAC059554-001 face is flat.
• IP67: sealing ring +
gasket + V-ring
3HAC058001-001
xx1600000052
3HAC058000-001 3HAC056656-001 Order: Look underneath the swing, there is

• swing 3HAC059554-001 a groove.
xx1600000053

7 Robot description
Continued
Swing installed on ro- Article number in What to order How to see which version is in-
bot (spare part num- WebConfig stalled on robot
ber)
3HAC059554-001 3HAC058387-001 Order: The swing has a bushing for fitting
• swing 3HAC059554-001 calibration tool for Axis Calibration.
xx1600001038

7 Robot description
7.3.3 Spare part versions for the axis-1 sealing ring on IP40/IP67 robots
7.3.3 Spare part versions for the axis-1 sealing ring on IP40/IP67 robots
Spare part versions for the axis-1 sealing ring on IP40/IP67 robots
Note
IRB 1200 has different axis-1 sealing ring versions that are not compatible with
each other. Always use the following list as a reference to check the sealing ring
installed on robot and order the correct spare parts.
Sealing ring installed Article number in What to order How to see which version is in-
on robot (spare part WebConfig stalled on robot
number)
3HAC044676-001 3HAC044676-001 Order: The sealing ring is flat.
• sealing ring 3HAC044676-
001
xx1600000125
3HAC056658-001 3HAC056658-001 Order: The sealing ring has one folded

• IP40: sealing ring wall on both sides.
3HAC058568-001
• IP67: sealing ring + gasket
+ V-ring 3HAC058001-001
xx1600000126
3HAC058568-001 3HAC058568-001 Order: The sealing ring is flat and the

• sealing ring 3HAC058568- edge is thinner.
001
xx1600001039

7 Robot description
7.3.4 Spare part versions for the housing on Type A robots
7.3.4 Spare part versions for the housing on Type A robots
Spare part versions for the housing on Type A robots
Note
IRB 1200 and IRB 1200 Type A have different housing versions that are not
compatible with each other. Always use the following list as a reference to check
the housing installed on robot and to order the correct spare parts.
Robot Housing installed on Article number in What to order How to see which version
variant robot (spare part WebConfig is installed on robot
number)
IRB 1200- 3HAC059680-001 3HAC044544-001 Order: The plane (encircled in the
7/0.7 • housing (IRB 1200-7/0.7 figure) on housing
): 3HAC059680-001 3HAC059680-001 has no
painting, while that on
3HAC059721-001 3HAC058389-001 Order: housing 3HAC059721-001
• housing (IRB 1200-7/0.7 is painted.
): 3HAC059721-001
xx1600001127
IRB 1200- 3HAC059681-001 3HAC04456-001 Order: The plane (encircled in the

5/0.9 • housing (IRB 1200-5/0.9 figure) on housing
): 3HAC059681-001 3HAC059681-001 has no
painting, while that on
3HAC059722-001 3HAC058393-001 Order: housing 3HAC059722-001
• housing (IRB 1200-5/0.9 is painted.
): 3HAC059722-001
xx1600001129

7 Robot description
7.3.5 Spare part versions for the tubular on Type A robots
7.3.5 Spare part versions for the tubular on Type A robots
Spare part versions for the tubular on Type A robots
Note
IRB 1200 and IRB 1200 Type A have different tubular versions that are not
compatible with each other. Always use the following list as a reference to check
the tubular installed on robot and to order the correct spare parts.
Tubular installed on robot Article number in What to order How to see which version is
(spare part number) WebConfig installed on robot
3HAC059693-001 3HAC044548-001 Order: The plane (encircled in the fig-
• tubular with sleeve: ure) on tubular 3HAC059693-
3HAC059693-001 001 has no painting, while that
on tubular 3HAC059723-001 is
3HAC059723-001 3HAC058390-001 Order: painted.
• tubular with sleeve:
3HAC059723-001
xx1600001128

7 Robot description
7.3.6 Spare part versions for the tubular cover on Clean Room robots
7.3.6 Spare part versions for the tubular cover on Clean Room robots
Spare part versions for the tubular cover on Clean Room robots
Note
IRB 1200 with protection type Clean Room has different tubular cover versions
that are not compatible with each other. Always use the following list as a
reference to check the tubular cover installed on robot and to order the correct
spare parts.
Tubular cover installed on Article number in What to order How to see which version is in-
Clean Room robots (spare WebConfig stalled on robot
part number)
3HAC056144-001 3HAC044550-001 Order: Tubular cover 3HAC056144-001
• tubular cover, clean has six screw holes.
room: 3HAC056144-
001
xx1600001117
3HAC059708-001 3HAC058929-001 Order: Tubular cover 3HAC059708-001

• tubular cover, clean has eight screw holes.
room: 3HAC059708-
001
xx1600001118

8 Reference information
8.1 Introduction
8.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

8.2 Applicable standards
Note
The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.
Standards, EN ISO
The product is designed in accordance with the requirements of:
Standard Description
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850:2015 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-1:2011 Robots for industrial environments - Safety requirements -Part
1 Robot
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
ISO 9283:1998 Manipulating industrial robots, performance criteria, and related
test methods
EN ISO 14644-1:2015 i Classification of air cleanliness
EN ISO 13732-1:2008 Ergonomics of the thermal environment - Part 1
EN 61000-6-4:2007 + EMC, Generic emission
A1:2011
IEC 61000-6-4:2006 +
A1:2010
(option 129-1)
EN 61000-6-2:2005 EMC, Generic immunity
IEC 61000-6-2:2005
EN IEC 60974-1:2012 ii Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-10:2014 ii Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part
1 General requirements
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
IEC 61340-5-1:2010 Protection of electronic devices from electrostatic phenomena
- General requirements
i Only robots with protection Clean Room.
ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.
European standards
EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles

Continued
EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design
Other standards
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
(option 429-1)
CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require-
(option 429-1) ments
ANSI/ESD S20.20:2007 Protection of Electrical and Electronic Parts, Assemblies and

Equipment (Excluding Electrically Initiated Explosive Devices)

8.3 Unit conversion
8.3 Unit conversion
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

8.4 Screw joints
8.4 Screw joints
General
This section describes how to tighten the various types of screw joints on the IRB
1200.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints.
It features special surface treatment (Gleitmo as described below) and is extremely
resistant to fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other
type of replacement screw is allowed. Using other types of screws will void any
warranty and may potentially cause serious damage or injury.
Gleitmo treated screws

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

Screws lubricated with Molycote 1000 should only be used when specified in the
repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Tighten to the torque as described in the procedures.
Lubricant Article number
Molycote 1000 (molybdenum disulphide grease) 3HAC042472-001
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatic tools.

8.4 Screw joints
Continued
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Note
A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.
Oil-lubricated screws with allen head screws

oil-lubricated screws with allen head screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670
M24 680 960 1150
Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M8 28 35
M10 55 70

8.4 Screw joints
Continued
Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M12 96 120
M16 235 280
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

8.5 Weight specifications
8.5 Weight specifications
Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. 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.
Example
Following is an example of a weight specification in a procedure:
Action Note
CAUTION
The robot weighs .

IRB 1200-5/0.9: 54 kg
IRB 1200-7/0.7: 52 kg
ingly.

8.6 Standard toolkit
8.6 Standard toolkit
General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.
Contents, standard toolkit
Qty Tool Rem.

1 Socket head cap 2-17 mm
1 Torque wrench 0.3-45 Nm
1 Torque wrench 55 Nm ± 5 Nm For securing robot to
foundation.
1 Ratchet head for torque wrench 1/2
1 Hex socket head cap no. 2.5 socket 1/2" bit L=110 mm
1 Small screwdriver
1 T-handle with ball head
1 Small cutting plier
1 Plastic mallet
1 Needle-nose plier

8.7 Special tools
8.7 Special tools
General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard toolkit on page 815, and of special tools, listed directly in the instructions
and also gathered in this section.
Special tools

8.7 Special tools
Axis-5 and axis-6 drive unit
Axis-4 gearbox, drive shaft

Axis-3 radial sealing and
Axis-4 motor with pulley

Axis-1 mechanical stop

Housing extender unit
(including sealings)
Tubular spare parts

Swing spare parts
Axis-4 timing belt
Axis-5 timing belt

Base spare parts
Axis-4 FPC unit
Axis-5 FPC unit

Cable harness
EIB/SMB unit
sealing ring
Signal lamp
Lower arm
and pulley
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 3 3 3
3HAC049704-001 Guide pin for axis-2 gear unit 3 3
3HAC049705-001 Guide pin for upper arm 3
3HAC049706-001 Guide pin for tilt unit (axis 5) 3 3
Lifting accessories
Lifting accessory, robot

3HAC049711-001 Includes lifting accessories, lifting 1 1
beam and screws.
xx1400000542
Roundsling, 2 m
- Length: 2 m. Lifting capacity: 100 1 1 1
kg.
Press, puller and unloading tools
Axis-1 sealing assembly tool set

3HAC049692-001 Used to refit the axis-1 radial 1
sealing.
xx1400000535

3HAC049694-001 Used to refit the radial sealing, if 1
replacement is needed.
xx1400000541

8.7 Special tools
Axis-5 and axis-6 drive unit
Axis-4 gearbox, drive shaft

Axis-3 radial sealing and


Housing extender unit
(including sealings)
Tubular spare parts

Swing spare parts
Axis-4 timing belt
Axis-5 timing belt

Base spare parts
Axis-4 FPC unit
Axis-5 FPC unit

Cable harness
EIB/SMB unit
sealing ring
Signal lamp
Lower arm
and pulley
Tools and equipment with spare part number:
(These tools can be ordered from ABB)

3HAC049697-001 Used to refit the axis-3 radial 1
sealing.
xx1400000538

3HAC049699-001 Used to refit the radial sealing, if 1 1 1
xx1400000539

3HAC049701-001 Used to refit the radial sealing, if 1 1 1
xx1400000540
Other tools
- 24 VDC power supply 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Calibration toolkit, manual
3HAC051256-001 1 1 1 1 1 1 1 1 1 1 1 1 1
calibration
Calibration tool box, Axis
3HAC062326-001 1 1 1 1 1 1 1 1 1 1 1 1 1
Calibration

8.8 Lifting accessories and lifting instructions
8.8 Lifting accessories and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting accessories,
which are specified in each procedure.
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.

9 Spare parts
9.1 Spare part lists and illustrations
9 Spare parts
9.1 Spare part lists and illustrations
Location
Spare parts and exploded views are not included in the manual but delivered as
a separate document for registered users on myABB Business Portal, www.mypo-
rtal.abb.com.

10 Circuit diagrams
10.1 Circuit diagrams
10 Circuit diagrams
Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.myportal.abb.com.
See the article numbers in the tables below.
Controllers
Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Compact 3HAC049406-003
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 3HAC024120-004
Circuit diagram - Spot welding cabinet 3HAC057185-001
Robots

Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 1600/1660 3HAC021351-003
Circuit diagram - IRB 4400/4450S 3HAC9821-1
Circuit diagram - IRB 6400RF 3HAC8935-1
Circuit diagram - IRB 6600 type A 3HAC13347-1
3HAC025744-001
Circuit diagram - IRB 6600 type B 3HAC13347-1
3HAC025744-001

10 Circuit diagrams
Continued

Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001
3HAC029940-001
3HAC025744-001
Circuit diagram - Product.ProductName 3HAC050778-003
Circuit diagram - IRB 910SC 3HAC056159-002

Index
Index brakes
testing function, 36
A C
Absolute Accuracy, calibration, 739 cabinet lock, 25, 31
aluminum cable package main
disposal, 794 replacing, 153
ambient humidity cabling, robot, 102
operation, 60 cabling between robot and controller, 102
storage, 60 calibrating
ambient temperature robot, 746
operation, 60 roughly, 743
storage, 60 calibrating robot, 746
assembly instructions, 49 calibration
assessment of hazards and risks, 20 Absolute Accuracy type, 738
axis-5 and axis-6 drive unit rough, 743
replacing, 715 standard type, 738
axis-5 FPC unit verification, 790
replacing, 253 when to calibrate, 740
axis-5 motor calibration, Absolute Accuracy, 739
replacing, 699 calibration manuals, 739
axis-5 timing belt calibration marks, 741
replacing, 709 calibration position
axis-4 FPC unit jogging to, 791
replacing, 222 scales, 741
axis-4 gear unit calibration scales, 741
replacing, 631 CalibWare, 738
axis-4 motor carbon dioxide extinguisher, 22
replacing, 673 cast iron
axis-4 pulley disposal, 794
replacing, 631 cleaning, 139
axis-4 shaft climbing on robot, 25
replacing, 631 Cold environments, 109
axis-4 timing belt connecting the robot and controller, cabling, 102
replacing, 684 connection
axis-3 external safety devices, 26
radial sealing copper
replacing, 379 disposal, 794
sealing ring
replacing, 379 D
axis-3 drive unit damage to mechanical stop, 121
replacing, 610 danger levels, 40
axis-3 gearbox dimensions
replacing, 610 robot, 87
axis-3 motor direction of axes, 742
replacing, 610 drive unit
axis-2 drive unit axis-3, 610
replacing, 589 axis-2, 589
Axis Calibration, 746
calibration tool E
article number, 749, 754 EIB/SMB battery
examining, 749 extension of lifetime, 129
installation position, 752 replacing, 129
overview of method, 746 EIB unit
procedure on FlexPendant, 754 replacing, 265
protective cover and protection plug, 752, 754 enabling device, 30
environmental information, 794
B equipment, robot, 87
base equipment on robot, fitting, 88
replacing, 447 ESD
batteries damage elimination, 33
disposal, 794 sensitive equipment, 33
handling, 37 external safety devices, 26
battery extra equipment, 87
replacing, 129
battery shutdown F
service routine, 129 fire extinguishing, 22

Index
fitting M
extra equipment, 88 main power connector, o-ring, 103
fitting, equipment, 87 maintenance intervals, 113
FlexPendant maintenance schedule, 113
jogging to calibration position, 791 mechanical stop
MoveAbsJ instruction, 791 axis-4, 416
updating revolution counters, 743 axis-3, 413
foundation axis-2, 410
requirements, 59 axis-1, 585
FPC unit mechanical stop location, 121
axis-5, 253 motor
axis-4, 222 axis-6, 715
axis-5, 699
G axis-4, 673
gearbox axis-3, 610
axis-3, 610 motor unit
axis-2, 589 axis-2, 589
gear unit mounting, equipment, 87
axis-4, 631 MoveAbsJ instruction, 791
Gravity Alpha, 82
Gravity Beta, 81 N
grease nation specific regulations, 19
disposal, 794 negative directions, axes, 742
neodymium
H disposal, 794
hanging NiCad
installed hanging, 25 disposal, 794
hazardous material, 794 nodular iron
height disposal, 794
installed at a height, 25
hold-to-run, 30 O
housing extender unit oil
replacing, 222 disposal, 794
sealings, 222 oil change
HRA, 20 safety risks, 38
humidity operating conditions, 60
operation, 60 option
storage, 60 signal lamp, 92
o-rings, enclosed with robot, 78, 103
I o-rings, extra at delivery, 50
information labels location, 116
inspecting P
information labels, 116 pedestal
mechanical stop, 121 installed on pedestal, 25
robot cabling, 115 positive directions, axes, 742
timing belts, 124 product standards, 808
installation protection classes, 61
equipment, 87 protection sleeve, base
instructions for assembly, 49 replacing, 447
integrator responsibility, 19 protection type, 61
intervals for maintenance, 113 protective equipment, 26
protective wear, 26
L pulley
labels axis-5, 699
robot, 42
lamp unit R
installing, 92 radial sealing
lifting axis-4, replacing, 222
accessory, 73 axis-2, replacing, 522
lifting accessory, 814 axis-1, replacing, 447
limitation of liability, 19 region specific regulations, 19
Lithium release brakes, 23
disposal, 794 replacing
loads on foundation, 58 axis-5 and axis-6 drive unit, 715
lower arm axis-5 FPC unit, 253
replacing, 280 axis-5 motor with pulley, 699
axis-5 pulley, 699

Index
axis-5 timing belt, 709 safety risk

axis-4 FPC unit, 222 electric parts, 31
axis-4 gear unit, 631 hot parts, 34
axis-4 motor, 673 hydraulic system, 35
axis-4 pulley, 631 installation, 25
axis-4 shaft, 631 oil change, 38
axis-4 timing belt, 684 operational disturbance, 25
axis-3 pneumatic system, 35
radial sealing, 379 service work, 25
sealing ring, 379 voltage, 31
axis-3 drive unit, 610 safety signals
axis-3 gearbox, 610 in manual, 40
axis-3 motor, 610 safety standards, 808
axis-2 drive unit, 589 safety zones, 20
axis-2 gearbox, 589 scales on robot, 741
axis-2 motor unit, 589 schedule of maintenance, 113
base, 447 screw joints, 811
cable package main, 153 securing, robot, 77
EIB unit, 265 signal lamp
housing extender unit, 222 installing, 92
lower arm, 280 replacing, 343
mechanical stop signals
axis-4, 416 safety, 40
axis-3, 413 SMB unit
axis-2, 410 replacing, 265
axis-1, 585 speed
protection sleeve, base, 447 adjusting, 109
radial sealing, axis-4, 222 stability, 67
radial sealing, axis-2, 522 stainless steel
radial sealing, axis-1, 447 disposal, 794
signal lamp, 343 standards, 808
SMB unit, 265 ANSI, 809
swing, 522 CAN, 809
tubular, 346 EN, 808
UL-lamp, 343 EN IEC, 808
requirements on foundation, 59 EN ISO, 808
responsibility and validity, 19 start of robot in cold environments, 109
revolution counters steel
storing on FlexPendant, 743 disposal, 794
updating, 743 storage conditions, 60
risk of tipping, 67 suspended mounting, 81
robot swing
dimensions, 87 replacing, 522
equipment, fitting, 87 symbols
labels, 42 safety, 40
protection class, 61 synchronization position, 743
protection types, 61 sync marks, 741
symbols, 42 system integrator requirements, 19
robot cabling system parameter
inspecting, 115 Gravity Alpha, 82
Gravity Beta, 81
S
safety T
brake testing, 36 temperatures
ESD, 33 operation, 60
fire extinguishing, 22 storage, 60
moving robots, 27 testing
release robot axes, 23 brakes, 36
signals, 40 three-position enabling device, 30
signals in manual, 40 tilted mounting, 81
symbols, 40 timing belts
symbols on robot, 42 inspecting, 124
test run, 28 torques on foundation, 58
working range, 29 Transportation bracket, 53, 67, 69
safety equipment tubular
signal lamp, 127 replacing, 346
safety fence, 20 turning

Index
accessory, 73 adjusting, 109

type A, 797 verifying calibration, 790
type B, 798
W
U wall mounting, 81
UL lamp weight, 57
replacing, 343 robot, 72, 814
updating revolution counters, 743
Z
V zero position
validity and responsibility, 19 checking, 791
velocity

ABB AB, Robotics
Robotics and Motion
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics

Robotics and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Engineering (Shanghai) Ltd.

Robotics and Motion
No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
ABB Inc.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC046983-001, Rev J, en


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© Copyright 2014 - 2018 ABB. All rights reserved.

© Copyright 2014 - 2018 ABB. All rights reserved.

2 Installation and commissioning 49

Product manual - IRB 1200 5

2.7 Electrical connections ........................................................................................ 102

6 Product manual - IRB 1200

7 Robot description 797

8 Reference information 807

9 Spare parts 821

10 Circuit diagrams 823

Product manual - IRB 1200 7

8 Product manual - IRB 1200

Overview of this manual

Who should read this manual?

Product manual scope

Continues on next page

Continues on next page

Continues on next page

Continues on next page

Continues on next page

14 Product manual - IRB 1200

Technical reference manuals

Continues on next page

16 Product manual - IRB 1200

How to read the product manual

Product manual - IRB 1200 17

1.1.1 Limitation of liability

Nation/region specific regulations

To be observed by the supplier of the complete system

Continues on next page

The integrator of the final application is required to perform an assessment of the

The integrator is responsible for the safety of the final application.

20 Product manual - IRB 1200

1.1.2 Protective stop and emergency stop

Product manual - IRB 1200 21

1.2 Safety actions

1.2.1 Fire extinguishing

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the

22 Product manual - IRB 1200

1.2.2 Emergency release of the robot axes

Product manual - IRB 1200 23

Switch off all main power switches in a MultiMove system.

24 Product manual - IRB 1200

1.3 Safety risks

1.3.1 Safety risks during installation and service work on robots

General risks during installation and service

Safety risks during operational disturbances

Continues on next page

Spare parts and special equipment

Connection of external safety devices

Personal protective equipment

26 Product manual - IRB 1200

1.3.2 Moving robots are potentially lethal

Product manual - IRB 1200 27

1.3.3 First test run may cause injury or damage

28 Product manual - IRB 1200

1.3.4 Work inside the working range of the robot

Product manual - IRB 1200 29

1.3.5 Enabling device and hold-to-run functionality

Three-position enabling device

The three-position enabling device is a push-button located on the teach pendant