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3hac046983 PM Irb 1200-En Rev J
3hac046983 PM Irb 1200-En Rev J
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
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
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
4.4.6 Replacing the axis-3 mechanical stop ......................................................... 413
4.4.7 Replacing the axis-4 mechanical stop ......................................................... 416
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
4.5.3 Replacing the axis-1 mechanical stop ......................................................... 585
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
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
5.5.4 Manual calibration method - calibrating axis 2 .............................................. 771
5.5.5 Manual calibration method - calibrating axis 3 .............................................. 775
5.5.6 Manual calibration method - calibrating axis 4 .............................................. 780
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
Index 825
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.
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.
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.
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.
Revision Description
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.
Revision Description
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.
Revision Description
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.
Revision Description
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.
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.
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.
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.
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.
Note
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.
Overview
The protective stops and emergency stops are described in the product manual
for the controller.
Note
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.
1.2.3 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
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.
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.
Allergenic material
See Environmental information on page 794 for specification of allergenic materials
in the product, if any.
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.
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.
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.
Note
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.
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.
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.
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.
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.
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
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.
1.3.12 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
Note
Note
Safe handling
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
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.
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).
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
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
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
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
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
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824
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
xx0900000827
Do not step
Warns that stepping on these parts can cause damage to the
parts.
xx1400002648
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
• Product manual - IRC5 Compact
2.2 Unpacking
xx1500000243
xx1500000242
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.
Further information
For installation information, see Orienting and securing the robot on page 77 and
Electrical connections on page 102.
Note
If the robot is delivered with option 636-1 Force Control Package, the
transportation bracket is installed on the force sensor.
xx1800000002
xx1500001605 xx1800000003
xx1800000004
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.
Action Note
1 Move the robot to an appropriate position.
WARNING
xx1500001399
2
CAUTION
Action Note
3 Remove the screws and washers.
CAUTION
xx1500001604
xx1800000005
xx1600001178
xx1500001400
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
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.
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
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
Note
The weight does not include tools and other equipment fitted on the robot.
Txy
Fz
Fxy
Tz
xx1100000521
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
Wall mounted
Suspended
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.
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.
2.2.5 Dimensions
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
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
Pos 1
Z
Pos 0
1642
Pos 9
Pos 6
Pos 8
342
Pos 5 Pos 4
901 901
xx1300000387
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
B (7/0.7)
B (5/0.9)
C (7/0.7)
C (5/0.9)
170°
xx1400000681
Working range
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!
xx1400000500
Transportation bracket
A transportation bracket is installed and delivered together with the robot for
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.
WARNING
Note
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.
For details, see Transportation bracket on page 53.
xx1400000501
Required equipment
WARNING
xx1400000500
2
CAUTION
xx1600001147
Action Note
4 Fit the lifting tools to the robot. Lifting accessory, robot: 3HAC049711-
Use the enclosed screws. 001
For robots with protection type Foundry Plus
(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
xx1400000511
Action Note
6 Fit the roundslings to the lifting beam and to Roundsling, 0.6 m
the overhead crane.
xx1400000501
7
CAUTION
8
WARNING
xx1600000005
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.
xx1400000030
xx1400000030
2
DANGER
Action Note
2 Supply +24V on pin 11 and 0V on pin 12.
Note
xx1400000031
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.
+ 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
xx0900000643
xx1500000241
4
CAUTION
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)
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)
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
Action Information
11 For robots with protection class IP67 (option Robots with manipulator cables
287-10) routed from the rear of the base:
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)
Fit the O-ring 3HAB3772-19 to the main power
connector on the robot base.
xx1500000243
xx1500000242
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
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).
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).
xx1400000682
xx1500000532
Note
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
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
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
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
Frame
30 ±0.15
2xM10 10
78 B
(A)
B
243
105
xx1400000590
Pos Description
A Holes on both sides
+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
+ 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
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.
xx1300000455
Required tools
Action Note
1
DANGER
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
xx1300000465
Action Note
7 Refit the cover on the upper arm housing. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm.
xx1300000456
Note
Note
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 2, hardware (mechanical stop) and software. Note! The axis 2 stop is a
fixed stop that must be installed during operation of robot!
• Axis 3, hardware (mechanical stop) and software. Note! The axis 3 stop is a
fixed stop that must be installed during operation of robot!
• Axis 4, hardware (mechanical stop) and software. Note! The axis 4 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
xx1700001293
xx1700001294
xx1700001295
xx1700001296
xx1700001297
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
• Replacing the axis-2 mechanical stop on page 410
• Replacing the axis-3 mechanical stop on page 413
• Replacing the axis-4 mechanical stop on page 416
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.
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.
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.
A
B
xx1600002016
A Diameter
B Diameter x10
xx1600001081
The O-ring specified below is delivered together with the robot and must be installed
to the main power connector during electrical 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
xx1500000242
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.
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
Connectors
The tables describes the connectors on base and tubular housing (upper arm).
Connectors, base
Air, connector
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
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
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.
For more information see:
• Product manual - IRC5
• Product manual - IRC5 Compact
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.
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.
For robots with protection type Clean
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
Inspecting the axis-2 mechanical stop x iv Inspecting mechanical stops on
page 121
Inspecting the axis-3 mechanical stop x iv Inspecting mechanical stops on
page 121
Inspecting the axis-4 mechanical stop - v
Inspecting the timing belts x Inspecting timing belts on page 124
Replacement/changing activities
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.
Inspection activities
Inspecting the signal lamp x Inspecting the signal lamp
(option) on page 127
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
replacing parts on page 144
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.
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
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
Illustration 2 of 2
$%% B
!
$%%
A A B
B
D
F E
UL lable
Lifting
instruction Warning
lable
IRB 1200-0.5/9
C B
B B
B
SECTION A-A VIEW B
IRB 1200 Option
Description Illustration
A Calibration label
B Warning label
Flash
xx1300001091
C Instruction label
Lifting of robot
xx1400000518
D Warning label
Heat
!
3HAC 4431-1/06
xx1300001087
29454489-16
xx1700000984
E Instruction label
Brake release
Moving robot !
Brake release buttons
3HAC 2577-1/ 04
xx1400000519
F UL label
G Rating label
H Warning label
Tip risk when loosening bolts
3HAC 037277-001
xx1400000527
xx1600001074
xx1600001075
3 Maintenance
3.3.2 Inspecting the information labels
Continued
6XSSOHPHQWDU\GRFXPHQW 'RFW\SH 'RFXPHQW 'HVFULSWLRQ
K Type A label
7<3($
: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
)RQW$ULDO
0DWHULDO7\SH 'LPHQVLRQ
&RORXU3ODWLQXPOLNH6:' 'UDZLQJ
'HVFULSWLRQ
)/LDQJ
6WDWXV 5HVSRQVLEOH'HSDUWPHQW 1RRIVK
1HZ
)/LDQJ
6WDWXV tion labels required for the robot.
5HVSRQVLEOH'HSDUWPHQW 1RRIVK
,QUHYLHZ '052&150
Missing, damaged or illegable
(&21XPEHU 'RFXPHQWQR 5HYLQG
+$&
labels must be replaced.
Inspecting, labels
Action Note
1
DANGER
Axis 1
xx1400000391
Axis 2
xx1400000389
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.
Note
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
Axis 4
xx1400000036
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.
Action Information
6 Check whether timing belts are slack
manually.
If the belt has no tension, adjust it!
xx1300000455
Action Note
2
DANGER
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.
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.
xx1300002574
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.
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 -
Action Note
1 Move the robot to its zero position. This is done in order to facilitate updating
of the revolution counter.
2
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
3
CAUTION
CAUTION
CAUTION
xx1400000812
Action Note
6 Valid for IRB 1200 Type B
Loose the connector screws.
xx1700000004
xx1700000005
Action Note
8 Disconnect the battery cable. Valid for IRB 1200 (no type spe-
cified) and IRB 1200 Type A
xx1300002571
xx1700000006
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
xx1300002579
xx1700000007
Action Note
2
CAUTION
xx1300002579
xx1700000007
Action Note
4 Connect the battery cable. Valid for IRB 1200 (no type spe-
cified) and IRB 1200 Type A
xx1300002571
xx1700000006
WARNING
Action Note
6 Valid for IRB 1200 Type B
Connect the connectors to the SMB unit.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING
xx1700000005
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
Action Note
9 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
Concluding procedure
Action Note
1 Update the revolution counters. See Updating revolution counters on
page 743.
2
CAUTION
Note
3
DANGER
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
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.
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
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.
For more information see:
• Product manual - IRC5
• Product manual - IRC5 Compact
4.2.1 Cut the paint or surface on the robot before replacing parts
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
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
Refitting
Note
Refitting is required only for robots with protection type Clean Room.
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
xx0900000125
Note
Note
After all repair work, wipe the robot free from particles with spirit on a lint free
cloth.
General
This section describes how to mount different types of seals.
Equipment
Rotating seals
The procedure below describes how to fit rotating seals.
CAUTION
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.
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.
4.2.4 Swing sealing plug for Clean Room robots and robots with food grade
lubrication
xx1600000264
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.
Required consumables
Consumable Art. no. Note
Sealant 3HAC026759-001 Sikaflex 521FC
For robots with protection type
Clean Room
Action Note
1 Cut the swing sealing plug through with a sharp
object to get access to the screws.
xx1600000206
xx1600000207
xx1600000208
Action Note
1 Mask the gap between the swing and the base.
xx1600000209
xx1600000210
xx1600000211
xx1600000261
Action Note
6 Refit the swing sealing plug.
xx1600000212
xx1600000213
xx1300002414
xx1400000410
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.
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
Equipment Article number Note
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.
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.
Action Note
2 Jog all axes to zero position.
xx1300002581
3
DANGER
2
CAUTION
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)
For robots with protection type
Note Foundry Plus (option 287-3)
xx1600001148
Tip
CAUTION
Action Note
1
DANGER
CAUTION
xx1300002390
CAUTION
Action Note
2
CAUTION
xx1300002400
xx1300002413
Action Note
5 Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 :
disconnect them.
xx1300002412
xx1400001471
xx1300002398
Action Note
7 Disconnect the remaining FPC connectors.
xx1300002399
2
CAUTION
CAUTION
xx1300000456
xx1300002494
Action Note
5 Disconnect the motor connectors.
Tip
xx1300002495
CAUTION
xx1300002420
Action Note
2 Remove the screw that fastens the air hose hold-
er.
CAUTION
xx1300002422
xx1300002421
xx1300002423
CAUTION
xx1300002424
Action Note
6 Valid for IRB 1200-5/0.9
Cut the cable straps at the bottom of the housing.
2
ELECTROSTATIC DISCHARGE (ESD)
3
CAUTION
CAUTION
CAUTION
xx1300002428
Action Note
7 Valid for IRB 1200 Type B
Loose the connector screws.
xx1700000004
xx1700000005
2
CAUTION
Action Note
4 Remove the fix sheet attachment screws in the
lower arm.
xx1300002426
CAUTION
xx1400001130
xx1600000205
Action Note
8 Remove the swing cable housing cover by remov-
ing the screws.
xx1300002431
xx1400001528
xx1300002432
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
xx1300002433
xx1300002434
xx1300002435
Action Note
14 Remove the axis-2 sealing ring by removing the
screws.
xx1400000020
Tip
xx1400000023
Action Note
1
DANGER
2
CAUTION
3
CAUTION
Action Note
4 Run a roundsling between the housing and Roundsling, 2 m
the lower arm.
CAUTION
xx1400000679
5
WARNING
6
CAUTION
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
2
CAUTION
Action Note
3 Remove the bottom cover. Rear connector interface:
xx1300000469
xx1400000403
Action Note
4 Remove the axis-1 motor bracket. Rear connector interface:
xx1300000470
xx1400000404
xx1300002496
2
CAUTION
Tip
xx1300000467
xx1300000471
Action Note
5 Pull out the base slightly and turn it aside.
Tip
xx1300000472
Action Note
1
CAUTION
xx1300002438
xx1300002446
2
CAUTION
xx1300002448
xx1300002456
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
2
CAUTION
xx1400000405
xx1400000406
Action Note
7 Remove the bracket inside the base by removing
the screws.
xx1400000407
xx1400000411
Note
Action Note
2 For robots with protection class IP67 (option Gasket for rear base cover:
287-10) 3HAC058566-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket on the base cover.
Replace if damaged.
xx1400000741
xx1300002448
Note
xx1400000480
Note
Cabling with bottom interface, 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 Clean the joints that have been opened. See Cut
the paint or surface on the robot before replacing
parts on page 144
2 Insert the cable package in and up through the
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
5 For robots with protection class IP67 (option Gasket for rear base cover:
287-10) 3HAC058566-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the base cover.
Replace if damaged.
xx1400000413
Action Note
8 Refit the base cover. Screws: 3HAB3409-212 (M4x16).
Tightening torque: 4 Nm.
xx1400000405
Note
xx1400000480
Note
Action Note
1 Clean the joints that have been opened. See Cut
the paint or surface on the robot before replacing
parts on page 144
2 Check the axis-1 sealing ring. Axis-1 sealing ring: 3HAC044676-
Replace if damaged. 001 / 3HAC058568-001 i
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
For robots with protection type Foundry Plus
(option 287-3)
On axis-1 sealing ring version 3HAC058568-001:
Check the gasket on the axis-1 sealing ring.
(See Spare part versions for the axis-1 sealing
ring on IP40/IP67 robots on page 803.)
Replace if damaged. xx1400000458
xx1600001149
xx1600001150
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
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.
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
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
xx1600000170
Action Note
4 Fit the guide pins to the drive unit. Guide pin for axis-1 gear unit:
3HAC049703-001
xx1300002566
CAUTION
xx1300002567
Note
Action Note
7 Remove the guide pins and refit the remain-
ing attachment screws and washers.
xx1300000523
xx1400000425
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).
Tightening torque: 1.5 Nm.
xx1300000467
Note
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 Reconnect the connectors and secure the
connectors to the bracket with cable straps.
xx1300002496
xx1300000470
xx1400000404
Action Note
4 For robots with protection class IP67 O-ring: 3HAB3772-86
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the O-ring.
Replace if damaged.
xx1400000412
xx1300000469
xx1400000403
Note
Action Note
6 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
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.
xx1400000476
3 For robots with protection class IP67 (option Gasket of plastic plate:
287-10) 3HAC044894-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing plastic
plate.
Replace if damaged.
xx1400000457
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
Action Note
6 For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641-
287-10) 004
For robots with protection type Foundry Plus
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
xx1400000454
Action Note
7 For robots with protection class IP67 (option Radial sealing with dust lip:
287-10) 3HAB3701-41
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the radial sealing.
Replace if damaged.
Note
xx1400000753
Tip
9 Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm.
xx1400000020
Action Note
10 Refit the cable housing with the screws. Screws: 3HAB3409-236 (M4x10).
Tightening torque: 3 Nm.
xx1300002435
Note
xx1400000481
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
xx1400000021
xx1300002432
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
Action Note
18 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056726-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000424
Action Note
21 Refit the cable housing cover. Cable housing cover of the swing:
Replace if damaged. 3HAC059678-001
: 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).
Tightening torque: 1.5 Nm.
xx1300002431
Note
22 For robots with protection type Foundry Plus Protection plug for lifting holes:
(option 287-3) 3HAC4836-24
Check the protection plugs for lifting holes.
Replace if damaged.
xx1600001151
Action Note
23 For robots with with protection type Clean Room Swing sealing plug:3HAC053687-
For robots with food grade lubrication 001
Refit the swing sealing plug.
Follow the procedure specified in Refitting the
swing sealing plug on page 151.
xx1600000205
24 Refit the lower arm bracket to the cable package. Tightening torque: 1.5 Nm.
CAUTION
xx1300002430
Note
Action Note
3 For robots with protection class IP67 (option Gasket on EIB/SMB cover:
287-10) 3HAC056728-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the EIB/SMB cover gasket.
Replace if damaged.
xx1400000475
WARNING
5 Valid for IRB 1200 (no type specified) and IRB xx1300002428
1200 Type A
Connect the lugs to the EIB/SMB cover.
6 Valid for IRB 1200 Type B
Connect the connectors to the SMB unit.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING
xx1700000005
Action Note
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
Action Note
9 Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm.
arm.
xx1300002426
Note
xx1400000483
Action Note
3 Guide the cable package into the upper arm,
through the housing.
Note
4 Refit the bracket to the sheet with two screws. Tightening torque: 1.5 Nm.
CAUTION
xx1300002424
5 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm.
xx1300002423
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).
Tightening torque: 4 Nm.
Tip
xx1300002422
xx1400001133
xx1300002420
Action Note
9 Apply grease to the cable package, cover all
moving area of the package.
xx1400000754
Note
CAUTION
xx1300002371
Action Note
2 Secure the connectors to the motor with a cable
strap.
xx1300002494
Tip
xx1300002399
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
Action Note
5 For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
xx1600000214
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
Action Note
10 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056724-001
For robots with protection type Foundry Plus PTFE film on cable housing cover:
(option 287-3) 3HAC044660-001
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000048
Action Note
13 Refit the cable housing cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm
xx1300002400
Note
Note
xx1400000738
Action Note
2 If equipped, reconnect the CP/CS connector.
For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
CAUTION
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 Gasket for tubular cover: 3HAC058822-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
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
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
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.
For robots with protection type Clean
Room
Remember to refit the extra two screws and
washers to the tubular cover.
xx1300002349
xx1600001153
Note
Note
Concluding procedure
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
For robots with with protection type Clean
Room
For robots with food grade lubrication
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
xx1300000456
Note
xx1600000215
Action Note
4 For robots with protection type Clean
Room:
Clean and paint the joints that have been
opened. See Cut the paint or surface on
the robot before replacing parts on page 144
Note
4.3.2 Replacing the axis-4 FPC unit, housing extender unit and housing extender
sealings
xx1300002419
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.
Required consumables
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.
2
CAUTION
3 Remove the covers on each side of the wrist by For robots with protection class
removing their screws. IP67 (option 287-10)
For robots with protection type
Note Foundry Plus (option 287-3)
xx1600001148
Action Note
2 Snap loose the motor connectors from their
holders and then disconnect them.
• R3.MP5
• R3.ME5
Tip
CAUTION
Action Note
1
DANGER
2
CAUTION
xx1300002350
Action Note
4 Remove the timing belt.
xx1300002351
xx1300002390
xx1300002352
2
CAUTION
Action Note
3 Disconnect the connectors shown in the figure.
xx1300002353
xx1300002355
xx1300002356
xx1300002357
Action Note
7 Support the weight of the wrist and remove the
screws and the washer.
xx1300002358
CAUTION xx1300002359
xx1300002611
2
CAUTION
Action Note
3 Remove the cable housing cover.
xx1300002400
xx1300002413
Action Note
5 Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 :
disconnect them.
xx1300002412
xx1400001471
xx1300002398
Action Note
7 Disconnect the remaining FPC connectors.
xx1300002399
xx1300002373
xx1600000262
xx1300002372
Action Note
5 Remove the housing extender unit.
Be careful not to damage the cabling.
xx1300002374
xx1300002415
Action Note
1
CAUTION
Action Note
2 Remove the FPC unit from the housing
extender unit by removing the screws.
CAUTION
xx1300002417
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 M2 variseal sealing: 3HAC044641-007
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
xx1300002418
Action Note
3 For robots with protection class IP67 Radial sealing with dust lip: 3HAB3701-48
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the radial sealing.
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
xx1400000436
Action Note
8 Screw the screws, little by little, to press
the sealing into place.
xx1400000437
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 Refit the FPC unit to the housing extender Tightening torque: 0.5 Nm.
unit and secure with the screws.
CAUTION
CAUTION
xx1300002611
Note
Note
xx1300002613
Action Note
3 For robots with protection type Clean Room
For robots with protection type Foundry Plus
Make sure the four cavities are fully filled with
glue. If not, fill glue again before the refitting.
xx1600000216
CAUTION
Note
xx1300002372
6 For robots with protection type Foundry Plus Screw sealing plug: 3HAC053685-
(option 287-3) 001
For robots with protection type Clean Room
For robots with food grade lubrication
Press in screw sealing plugs to cover the screws.
xx1600000263
Action Note
7 Fit and secure the axis-4 FPC unit screws. Tightening torque: 0.3 Nm.
xx1300002373
Note
Tip
xx1300002399
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
Action Note
5 For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
xx1600000214
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
Action Note
10 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056724-001
For robots with protection type Foundry Plus PTFE film on cable housing cover:
(option 287-3) 3HAC044660-001
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000048
Action Note
13 Refit the cable housing cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm
xx1300002400
Note
Note
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.
Be careful not to damage the FPC cabling and the
connectors.
CAUTION xx1300002359
xx1300002611
3 Refit the washer while at the same time putting Washer: 3HAC044869-001
the cables through its center.
Replace washer, if damaged.
xx1400000001
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
xx1300002356
Action Note
8 Reconnect the air hoses.
CAUTION
xx1300002355
xx1300002353
Note
CAUTION
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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Refit the timing belt on the pulley.
xx1300002351
xx1300002350
Action Note
5 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
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
CAUTION
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 For robots with protection class IP67 Gasket for tubular cover: 3HAC058822-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
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
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
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.
For robots with protection type Clean
Room
Remember to refit the extra two screws and
washers to the tubular cover.
xx1300002349
xx1600001153
Note
Note
Concluding procedure
Action Note
1
CAUTION
Note
xx1300002397
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.
Required consumables
xx1300002581
2
DANGER
3
CAUTION
Action Note
4 Remove the tubular cable housing cover.
xx1300002389
xx1300002390
xx1300002391
Note
xx1300002393
xx1300002582
xx1300002394
Action Note
5 Disconnect the axis-6 motor connectors and re-
move the FPC unit completely.
xx1300002395
Action Note
1
WARNING
xx1300002395
Action Note
4 Carefully refit the FPC unit and secure with Tightening torque: 0.3 Nm.
screws.
Note
xx1300002394
Note
xx1300002609
xx1300002393
Action Note
7 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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Check the sealing. M2 variseal sealing: 3HAC044641-009
Replace if damaged.
CAUTION
xx1300002396
xx1300002608
Action Note
6 Fit the circular part of the radial sealing Axis-5 sealing assembly tool set:
assembly tool against the radial sealing. 3HAC049701-001
7 Fit the tool plate to the other side of the
tubular cable housing with the six screws
M6x40.
xx1400000485
xx1400000486
Note
xx1300002610
Note
3 Refit the tubular cable housing with the screws. Tightening torque: 1.5 Nm.
Tubular cable housing:
3HAC059695-001
: 3HAC056143-001 (used with pro-
tection type Clean Room)
Tubular cable housing, Clean
Room
Tubular cable housing, food grade
lubrication
xx1300002392
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 Refit the connector plate and secure with Tightening torque: 0.3 Nm.
the M3 screws.
xx1400001401
xx1400001402
Note
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 Gasket for tubular cable housing cover:
(option 287-10) 3HAC056707-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
xx1300002389
Note
Note
Concluding procedure
Action Note
1
CAUTION
Note
2
DANGER
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
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.
Action Note
1
DANGER
2
CAUTION
Action Note
3 Remove the lower arm cable housing cov-
er.
xx1300002400
2
ELECTROSTATIC DISCHARGE (ESD)
3
CAUTION
Action Note
4 Remove the EIB/SMB cover attachment screws
on the lower arm and carefully open the cover.
CAUTION
CAUTION
xx1300002428
xx1700000004
Action Note
8 Valid for IRB 1200 Type B
Disconnect the connectors on the SMB unit.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
Remove the EIB/SMB cover completely from the
lower arm.
xx1700000005
Removing the EIB unit (IRB 1200 no type specified and IRB 1200 Type A)
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
2
CAUTION
xx1300002571
Action Note
4 Remove the battery pack plate by removing the
screws.
xx1300002572
xx1300002573
2
CAUTION
Action Note
3 Disconnect the battery cable.
xx1700000006
xx1700000008
xx1700000009
Refitting the EIB unit (IRB 1200 no type specified and IRB 1200 Type A)
Action Note
1
ELECTROSTATIC DISCHARGE (ESD)
xx1300002573
4 Refit the battery pack plate with the screws. Tightening torque: 1.5 Nm.
xx1300002572
Action Note
5 Reconnect the battery cable.
xx1300002571
Note
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
xx1700000006
Action Note
6 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
xx1400000475
Action Note
4 Valid for IRB 1200 (no type specified) and IRB
1200 Type A
Connect the connectors to the EIB unit.
• 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.
6 Valid for IRB 1200 Type B
Connect the connectors to the SMB unit.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING
xx1700000005
xx1700000004
Action Note
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
9 Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm.
arm.
xx1300002426
Note
Concluding procedure
Action Note
1 For robots with protection class IP67 Gasket on cable housing cover:
(option 287-10) 3HAC056724-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
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.
Action Note
4 Refit the cable housing cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm.
xx1300002400
Note
Note
7
DANGER
xx1400000423
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.
Required consumables
Consumable Art. no. Note
Cable straps -
Cleaning agent - Loctite 7063
Locking liquid 3HAB7116-1 Loctite 243
Flange sealing 12340011-116 Loctite 574
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.
Sealant 3HAC026759-001 Sikaflex 521FC
For robots with protection type
Clean Room
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.
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Jog all axes to zero position.
xx1300002581
Action Note
3
DANGER
2
CAUTION
3 Remove the covers on each side of the wrist by For robots with protection class
removing their screws. IP67 (option 287-10)
For robots with protection type
Note Foundry Plus (option 287-3)
xx1600001148
Tip
CAUTION
Action Note
1
DANGER
CAUTION
xx1300002390
CAUTION
2
CAUTION
xx1300002400
Action Note
4 Remove the plate.
xx1300002413
5 Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 :
disconnect them.
xx1300002412
xx1400001471
Action Note
6 Remove the small cover of the housing.
xx1300002398
xx1300002399
2
CAUTION
Action Note
3 Remove the cover from the upper arm housing.
CAUTION
xx1300000456
xx1300002494
Tip
xx1300002495
Action Note
2 Pull out the axis-3 motor connectors from the
housing and disconnect them.
CAUTION
xx1300002420
CAUTION
xx1300002422
xx1300002421
Action Note
4 Remove the screws that fasten the fix sheet to
the motor.
xx1300002423
CAUTION
xx1300002424
2
ELECTROSTATIC DISCHARGE (ESD)
3
CAUTION
Action Note
4 Remove the EIB/SMB cover attachment screws
on the lower arm and carefully open the cover.
CAUTION
CAUTION
xx1300002428
xx1700000004
Action Note
8 Valid for IRB 1200 Type B
Disconnect the connectors on the SMB unit.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
Remove the EIB/SMB cover completely from the
lower arm.
xx1700000005
2
CAUTION
xx1300002426
Action Note
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
xx1400001130
xx1600000205
xx1300002431
Action Note
9 Cut the cable straps.
xx1400001528
xx1300002432
CAUTION
xx1300002433
Action Note
12 Disconnect the motor connectors.
• R2.ME2
• R2.MP2
xx1300002434
xx1300002435
xx1400000020
Tip
Action Note
16 Loosen the plastic plate from the cable housing
in order to facilitate continued removal of the cable
package .
xx1400000023
Action Note
1
DANGER
2
CAUTION
xx1300002529
Action Note
1
DANGER
2
CAUTION
xx1300002528
4
CAUTION
Action Note
6 Remove the upper arm screws.
WARNING
xx1300002531
7 Fit guide pins to the upper arm. Guide pin for upper arm: 3HAC049705-001
Always use three guide pins together!
xx1400000771
xx1300002533
Action Note
1
DANGER
2
CAUTION
xx1300002551
WARNING
xx1300002552
Action Note
5 Fit guide pins to the gearbox. Guide pin for axis-2 gear unit:
3HAC049704-001
Always use three guide pins together!
xx1300002563
Tip
xx1300002553
Action Note
1
DANGER
2
CAUTION
Action Note
3
CAUTION
WARNING
xx1400000008
xx1300002555
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
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).
3 For robots with protection class IP67
(option 287-10)
For robots with protection type Foundry
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 lower arm.
Note
xx1400000006
Action Note
4 Carefully insert the complete drive unit.
Note
xx1300002580
xx1400000795
xx1300002554
Note
Action Note
7 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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Check the o-ring. O-ring: 3HAC048939-001
Replace if damaged.
xx1300002556
Note
xx1400001403
Action Note
4 Fit guide pins to the gearbox. Guide pin for axis-2 gear unit:
3HAC049704-001
xx1300002562
CAUTION
xx1400000453
xx1300002563
Action Note
7 Refit the lower arm screws and washers, Screws: 3HAB3409-51 (M10x30).
using locking liquid Loctite 243.
Secure the screws but do not tighten yet.
xx1300002564
Note
xx1300002565
Action Note
10 For robots with protection class IP67 Gasket on swing cover: 3HAC056727-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the swing cover gasket.
Replace if damaged.
xx1400000007
xx1300002551
Action Note
12 For robots with protection type Foundry Protection plug for lifting holes:
Plus (option 287-3) 3HAC4836-24
Check the protection plugs for lifting holes.
Replace if damaged.
xx1600001151
xx1600000217
xx1600001154
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Fit guide pins to the axis-3 gear unit. Guide pin for upper arm: 3HAC049705-001
Always use three guide pins together!
xx1400000027
CAUTION
xx1400000474
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
xx1400000029
Action Note
7 For robots with protection class IP67 Gasket on lower arm cover: 3HAC056725-
(option 287-10) 001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the lower arm cover gasket.
Replace if damaged.
xx1400000047
xx1300002528
Note
Action Note
9 For robots with protection class IP67 Gasket on lower arm cable housing:
(option 287-10) 3HAC044895-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the cable housing gasket.
Replace if damaged.
xx1400000414
Note
Note
Action Note
11 Refit the cable housing of the lower arm. Tightening torque: 3 Nm
xx1400000785
Note xx1600000218
xx1600001155
Note
xx1400000476
3 For robots with protection class IP67 (option Gasket of plastic plate:
287-10) 3HAC044894-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing plastic
plate.
Replace if damaged.
xx1400000457
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
Action Note
6 For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641-
287-10) 004
For robots with protection type Foundry Plus
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
xx1400000454
Action Note
7 For robots with protection class IP67 (option Radial sealing with dust lip:
287-10) 3HAB3701-41
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the radial sealing.
Replace if damaged.
Note
xx1400000753
Tip
9 Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm.
xx1400000020
Action Note
10 Refit the cable housing with the screws. Screws: 3HAB3409-236 (M4x10).
Tightening torque: 3 Nm.
xx1300002435
Note
xx1400000481
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
xx1400000021
xx1300002432
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
Action Note
18 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056726-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000424
Action Note
21 Refit the cable housing cover. Cable housing cover of the swing:
Replace if damaged. 3HAC059678-001
: 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).
Tightening torque: 1.5 Nm.
xx1300002431
Note
22 For robots with protection type Foundry Plus Protection plug for lifting holes:
(option 287-3) 3HAC4836-24
Check the protection plugs for lifting holes.
Replace if damaged.
xx1600001151
Action Note
23 For robots with with protection type Clean Room Swing sealing plug:3HAC053687-
For robots with food grade lubrication 001
Refit the swing sealing plug.
Follow the procedure specified in Refitting the
swing sealing plug on page 151.
xx1600000205
24 Refit the lower arm bracket to the cable package. Tightening torque: 1.5 Nm.
CAUTION
xx1300002430
Note
Action Note
3 For robots with protection class IP67 (option Gasket on EIB/SMB cover:
287-10) 3HAC056728-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the EIB/SMB cover gasket.
Replace if damaged.
xx1400000475
WARNING
5 Valid for IRB 1200 (no type specified) and IRB xx1300002428
1200 Type A
Connect the lugs to the EIB/SMB cover.
6 Valid for IRB 1200 Type B
Connect the connectors to the SMB unit.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING
xx1700000005
Action Note
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
Action Note
9 Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm.
arm.
xx1300002426
Note
xx1400000483
Action Note
3 Guide the cable package into the upper arm,
through the housing.
Note
4 Refit the bracket to the sheet with two screws. Tightening torque: 1.5 Nm.
CAUTION
xx1300002424
5 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm.
xx1300002423
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).
Tightening torque: 4 Nm.
Tip
xx1300002422
xx1400001133
xx1300002420
Action Note
9 Apply grease to the cable package, cover all
moving area of the package.
xx1400000754
Note
CAUTION
xx1300002371
Action Note
2 Secure the connectors to the motor with a cable
strap.
xx1300002494
Tip
xx1300002399
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
Action Note
5 For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
xx1600000214
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
Action Note
10 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056724-001
For robots with protection type Foundry Plus PTFE film on cable housing cover:
(option 287-3) 3HAC044660-001
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000048
Action Note
13 Refit the cable housing cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm
xx1300002400
Note
Note
xx1400000738
Action Note
2 If equipped, reconnect the CP/CS connector.
For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
CAUTION
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 Gasket for tubular cover: 3HAC058822-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
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
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
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.
For robots with protection type Clean
Room
Remember to refit the extra two screws and
washers to the tubular cover.
xx1300002349
xx1600001153
Note
Note
Concluding procedure
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
For robots with with protection type Clean
Room
For robots with food grade lubrication
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
xx1300000456
Note
xx1600000215
Action Note
4
CAUTION
Note
xx1300000455
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.
Action Note
1
DANGER
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.
xx1300000456
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
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket.
Replace if damaged.
xx1400000477
10 Refit the cover on the upper arm housing. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm.
Note
Note
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.
Required consumables
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.
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
Action Note
2 Jog all axes to zero position.
xx1300002581
3
DANGER
2
CAUTION
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)
For robots with protection type
Note Foundry Plus (option 287-3)
xx1600001148
xx1300002390
Action Note
3 Remove the connector plate by first removing the
screws.
xx1300002391
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Check the sealing. M2 variseal sealing: 3HAC044641-009
Replace if damaged.
CAUTION
xx1300002396
Action Note
3 For robots with protection class IP67 Radial sealing: 3HAB3701-42
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the radial sealing.
Replace if damaged, as described below.
If undamaged and properly seated, skip to
the next procedure table.
xx1300002608
xx1400000485
Action Note
8 Screw the screws, little by little, to press
the sealing into place.
xx1400000486
Note
xx1300002610
Note
Action Note
3 Refit the tubular cable housing with the screws. Tightening torque: 1.5 Nm.
Tubular cable housing:
3HAC059695-001
: 3HAC056143-001 (used with pro-
tection type Clean Room)
Tubular cable housing, Clean
Room
Tubular cable housing, food grade
lubrication
xx1300002392
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Refit the connector plate and secure with Tightening torque: 0.3 Nm.
the M3 screws.
xx1400001401
Action Note
3 Secure the three M2.5 screws. Tightening torque: 0.3 Nm.
xx1400001402
Note
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 For robots with protection class IP67 Gasket for tubular cover: 3HAC058822-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
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
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
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.
For robots with protection type Clean
Room
Remember to refit the extra two screws and
washers to the tubular cover.
xx1300002349
xx1600001153
Note
Note
2
CAUTION
3 Remove the covers on each side of the wrist by For robots with protection class
removing their screws. IP67 (option 287-10)
For robots with protection type
Note Foundry Plus (option 287-3)
xx1600001148
Tip
CAUTION
Action Note
1
DANGER
2
CAUTION
xx1300002350
Action Note
4 Remove the timing belt.
xx1300002351
xx1300002390
xx1300002352
2
CAUTION
Action Note
3 Disconnect the connectors shown in the figure.
xx1300002353
xx1300002355
xx1300002356
xx1300002357
Action Note
7 Support the weight of the wrist and remove the
screws and the washer.
xx1300002358
CAUTION xx1300002359
xx1300002611
2
CAUTION
Action Note
3 Remove the cable housing of the tubular by first
removing the screws.
Note
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
xx1300002470
xx1600001126
3 For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641-
287-10) 008
For robots with protection type Foundry Plus
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
xx1300002493
Note
Action Note
5 Fit guide pins to the axis-5 gearbox. Guide pin for tilt unit (axis 5):
3HAC049706-001
xx1300002568
xx1600000219
xx1600000220
Action Note
7 Refit the drive unit and secure with the screws Attachment screws: 3HAB3409-236
and washers. (M4x10).
Secure the screws but do not tighten yet.
Note
xx1300002569
Note
xx1300002570
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 Check the sealing. M2 variseal sealing: 3HAC044641-009
Replace if damaged.
CAUTION
xx1300002396
xx1300002608
xx1400000485
Action Note
8 Screw the screws, little by little, to press
the sealing into place.
xx1400000486
Note
xx1300002610
Note
Action Note
3 Refit the tubular cable housing with the screws. Tightening torque: 1.5 Nm.
Tubular cable housing:
3HAC059695-001
: 3HAC056143-001 (used with pro-
tection type Clean Room)
Tubular cable housing, Clean
Room
Tubular cable housing, food grade
lubrication
xx1300002392
Note
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.
Be careful not to damage the FPC cabling and the
connectors.
CAUTION xx1300002359
xx1300002611
3 Refit the washer while at the same time putting Washer: 3HAC044869-001
the cables through its center.
Replace washer, if damaged.
xx1400000001
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
xx1300002356
Action Note
8 Reconnect the air hoses.
CAUTION
xx1300002355
xx1300002353
Note
CAUTION
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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Refit the timing belt on the pulley.
xx1300002351
xx1300002350
Action Note
5 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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Refit the connector plate and secure with Tightening torque: 0.3 Nm.
the M3 screws.
xx1400001401
xx1400001402
Note
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
CAUTION
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 Gasket for tubular cover: 3HAC058822-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cover gasket.
Replace if damaged.
xx1400000034
Action Note
3 For robots with protection class IP67 Gasket for tubular cable housing cover:
(option 287-10) 3HAC056707-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
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.
For robots with protection type Clean
Room
Remember to refit the extra two screws and
washers to the tubular cover.
xx1300002349
xx1600001153
Note
Note
Concluding procedures
Action Note
1 Clean and paint the joints that have been
opened. See Cut the paint or surface on
the robot before replacing parts on page 144
Note
xx1400000336
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.
Required consumables
Action Note
1 Jog all axes to zero position.
xx1300002581
2
DANGER
3
CAUTION
xx1300002389
Tip
CAUTION
Action Note
1
DANGER
CAUTION
xx1300002390
CAUTION
2
CAUTION
xx1300002400
Action Note
4 Remove the plate.
xx1300002413
5 Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 :
disconnect them.
xx1300002412
xx1400001471
Action Note
6 Remove the small cover of the housing.
xx1300002398
xx1300002399
2
CAUTION
Action Note
3 Remove the cover from the upper arm housing.
CAUTION
xx1300000456
xx1300002494
Tip
xx1300002495
Action Note
2 Pull out the axis-3 motor connectors from the
housing and disconnect them.
CAUTION
xx1300002420
CAUTION
xx1300002422
xx1300002421
Action Note
4 Remove the screws that fasten the fix sheet to
the motor.
xx1300002423
CAUTION
xx1300002424
Action Note
1
DANGER
2
CAUTION
Action Note
4 Remove the cable housing of the lower arm
by removing the screws.
xx1300002529
2
CAUTION
xx1400000473
Action Note
4 Remove the axis-3 radial sealing.
xx1400000334
2
CAUTION
xx1400000332
Action Note
4 Use screws in the two press out holes to
press the sealing ring out.
xx1400000333
Note
Action Note
3 Refit the axis-3 sealing ring by securing the Tightening torque: 1.5 Nm
screws.
Note
xx1400000333
xx1400000332
Note
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
Action Note
8 For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641-
287-10) 006
For robots with protection type Foundry Plus
(option 287-3)
Fit a new M2 variseal sealing.
CAUTION
xx1400000473
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 For robots with protection class IP67 Gasket on lower arm cable housing:
(option 287-10) 3HAC044895-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the cable housing gasket.
Replace if damaged.
xx1400000414
Note
Note
Action Note
4 Refit the cable housing of the lower arm. Tightening torque: 4 Nm.
xx1300002529
Note xx1600000218
Note
Action Note
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
Note
4 Refit the bracket to the sheet with two screws. Tightening torque: 1.5 Nm.
CAUTION
xx1300002424
Action Note
5 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm.
xx1300002423
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).
Tightening torque: 4 Nm.
Tip
xx1300002422
xx1400001133
Action Note
8 Reconnect the axis-3 motor connectors.
xx1300002420
xx1400000754
Note
CAUTION
xx1300002371
xx1300002494
Tip
xx1300002399
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
Action Note
5 For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
xx1600000214
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
Action Note
10 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056724-001
For robots with protection type Foundry Plus PTFE film on cable housing cover:
(option 287-3) 3HAC044660-001
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000048
Action Note
13 Refit the cable housing cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm
xx1300002400
Note
Note
xx1400000738
Action Note
2 If equipped, reconnect the CP/CS connector.
For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
CAUTION
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 Gasket for tubular cable housing cover:
(option 287-10) 3HAC056707-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
Action Note
3 Refit the cover to the cable housing. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm.
xx1300002389
Note
Note
Concluding procedure
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
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the gasket.
Replace if damaged.
xx1400000477
Action Note
2 Refit the upper arm housing cover with the Screws: 3HAB3409-207 (M3x8).
screws. Tightening torque: 1.5 Nm.
CAUTION
xx1300000456
Note
xx1600000215
4
CAUTION
Note
5
DANGER
xx1400000389
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.
Action Note
1 Jog the robot to a position where the
mechanical stop is most easily accessed.
2
DANGER
Action Note
1
DANGER
2
CAUTION
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
Note
6
DANGER
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.
Action Note
1 Jog the robot to a position where the
mechanical stops are most easily ac-
cessed.
2
DANGER
Action Note
1
DANGER
2
CAUTION
xx1400000387
Note
Action Note
6
DANGER
WARNING
xx1300002416
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.
Required consumables
Consumable Art. no. Note
Cleaning agent - Loctite 7063
Flange sealing 12340011-116 Loctite 574
Used with protection class IP67.
Used with protection type
Foundry Plus.
Flange sealing 3HAC026759-001 Sikaflex 521FC
Locking liquid 3HAB7116-1 Loctite 243
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.
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Jog all axes to zero position.
xx1300002581
Action Note
3
DANGER
2
CAUTION
3 Remove the covers on each side of the wrist by For robots with protection class
removing their screws. IP67 (option 287-10)
For robots with protection type
Note Foundry Plus (option 287-3)
xx1600001148
Tip
CAUTION
Action Note
1
DANGER
2
CAUTION
xx1300002350
Action Note
4 Remove the timing belt.
xx1300002351
xx1300002390
xx1300002352
2
CAUTION
Action Note
3 Disconnect the connectors shown in the figure.
xx1300002353
xx1300002355
xx1300002356
xx1300002357
Action Note
7 Support the weight of the wrist and remove the
screws and the washer.
xx1300002358
CAUTION xx1300002359
xx1300002611
2
CAUTION
Action Note
3 Remove the cable housing cover.
xx1300002400
xx1300002413
Action Note
5 Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 :
disconnect them.
xx1300002412
xx1400001471
xx1300002398
Action Note
7 Disconnect the remaining FPC connectors.
xx1300002399
xx1300002373
xx1600000262
xx1300002372
Action Note
5 Remove the housing extender unit.
Be careful not to damage the cabling.
xx1300002374
xx1300002415
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 For robots with protection class IP67 M2 variseal sealing: 3HAC044641-007
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
xx1300002418
3 For robots with protection class IP67 Radial sealing with dust lip: 3HAB3701-48
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the radial sealing.
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
Action Note
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
xx1400000437
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Fit the mechanical stop screw to the axis- Screws: 3HAB3409-231 (M4x8).
4 shaft. Tightening torque: 4 Nm.
xx1400000393
xx1300002415
Note
Note
Note
xx1300002613
xx1600000216
CAUTION
Note
Action Note
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
For robots with protection type Clean Room
For robots with food grade lubrication
Press in screw sealing plugs to cover the screws.
xx1600000263
7 Fit and secure the axis-4 FPC unit screws. Tightening torque: 0.3 Nm.
xx1300002373
Note
Action Note
2 Reconnect the FPC connectors.
Tip
xx1300002399
3 Reconnect the FPC connectors and push them Cable layout in IRB 1200-7/0.7 :
into place inside the housing.
Tip
xx1300002412
xx1400001471
Action Note
5 For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
xx1600000214
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
Action Note
10 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056724-001
For robots with protection type Foundry Plus PTFE film on cable housing cover:
(option 287-3) 3HAC044660-001
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000048
Action Note
13 Refit the cable housing cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm
xx1300002400
Note
Note
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.
Be careful not to damage the FPC cabling and the
connectors.
CAUTION xx1300002359
xx1300002611
3 Refit the washer while at the same time putting Washer: 3HAC044869-001
the cables through its center.
Replace washer, if damaged.
xx1400000001
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
xx1300002356
Action Note
8 Reconnect the air hoses.
CAUTION
xx1300002355
xx1300002353
Note
CAUTION
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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Refit the timing belt on the pulley.
xx1300002351
xx1300002350
Action Note
5 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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Refit the connector plate and secure with Tightening torque: 0.3 Nm.
the M3 screws.
xx1400001401
xx1400001402
Note
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
CAUTION
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 Gasket for tubular cover: 3HAC058822-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cover gasket.
Replace if damaged.
xx1400000034
Action Note
3 For robots with protection class IP67 Gasket for tubular cable housing cover:
(option 287-10) 3HAC056707-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
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.
For robots with protection type Clean
Room
Remember to refit the extra two screws and
washers to the tubular cover.
xx1300002349
xx1600001153
Note
Note
Concluding procedure
Action Note
1 Clean and paint the joints that have been
opened. See Cut the paint or surface on
the robot before replacing parts on page 144
Note
4.5.1 Replacing the base spare parts (base, axis-1 radial sealing, protection sleeve)
xx1400000395
xx1400000269
xx1400000396
xx1400000471 xx1400000471
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.
Required consumables
Equipment Art. no. Note
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.
Grease 3HAC058065-001 Used for lubrication of radial
sealing surface between base
and swing.
For robots with protection class
IP67 (option 287-10)
For robots with protection type
Foundry Plus (option 287-3).
Sealant 3HAC026759-001 Sikaflex 521FC
For robots with protection type
Clean Room.
For robots with protection class
IP67 (option 287-10)
For robots with protection type
Foundry Plus (option 287-3).
Action Note
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.
xx1300002581
3
DANGER
Action Note
4
CAUTION
xx1300002389
Tip
CAUTION
Action Note
1
DANGER
CAUTION
xx1300002390
CAUTION
Action Note
2
CAUTION
xx1300002400
xx1300002413
Action Note
5 Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 :
disconnect them.
xx1300002412
xx1400001471
xx1300002398
Action Note
7 Disconnect the remaining FPC connectors.
xx1300002399
2
CAUTION
CAUTION
xx1300000456
xx1300002494
Action Note
5 Disconnect the motor connectors.
Tip
xx1300002495
CAUTION
xx1300002420
Action Note
2 Remove the screw that fastens the air hose hold-
er.
CAUTION
xx1300002422
xx1300002421
xx1300002423
CAUTION
xx1300002424
Action Note
6 Valid for IRB 1200-5/0.9
Cut the cable straps at the bottom of the housing.
2
ELECTROSTATIC DISCHARGE (ESD)
3
CAUTION
CAUTION
CAUTION
xx1300002428
Action Note
7 Valid for IRB 1200 Type B
Loose the connector screws.
xx1700000004
xx1700000005
2
CAUTION
Action Note
4 Remove the fix sheet attachment screws in the
lower arm.
xx1300002426
CAUTION
xx1400001130
xx1600000205
Action Note
8 Remove the swing cable housing cover by remov-
ing the screws.
xx1300002431
xx1400001528
xx1300002432
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
xx1300002433
xx1300002434
xx1300002435
Action Note
14 Remove the axis-2 sealing ring by removing the
screws.
xx1400000020
Tip
xx1400000023
Action Note
1
DANGER
2
CAUTION
3
CAUTION
Action Note
4 Run a roundsling between the housing and Roundsling, 2 m
the lower arm.
CAUTION
xx1400000679
5
WARNING
6
CAUTION
Action Note
7 Loosen the robot from the foundation by
removing the foundation attachment
screws and put the robot on its side.
xx1400000680
2
CAUTION
Tip
xx1300000467
Action Note
4 Remove the screws and washers.
xx1300000471
Tip
xx1300000472
Action Note
1
CAUTION
xx1300002438
Action Note
4 Remove the cable bracket from the cabling, if the
cable package is to be replaced with a new spare
part.
xx1300002446
Action Note
1
CAUTION
xx1400000780
Action Note
4 Remove the radial sealing.
xx1400000270
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection type Clean
Room
Apply a little grease to the sealing when
replacing the radial sealing and wipe clean
after the replacement.
3 Fit the new sealing in its groove in the Radial sealing with dust lip: 3HAB3701-47
base.
xx1400000270
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
CAUTION
xx1400000780
Note
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.
Action Note
1
CAUTION
CAUTION
Note
Action Note
1
CAUTION
xx1400000776
xx1400000777
Action Note
7 Apply grease on the inner surface of the protec-
tion sleeve, also on the bottom surface.
xx1400000778
Note
Action Note
1
DANGER
2
CAUTION
Action Note
3 Remove the bottom cover. Rear connector interface:
xx1300000469
xx1400000403
Action Note
4 Remove the axis-1 motor bracket. Rear connector interface:
xx1300000470
xx1400000404
xx1300002496
2
CAUTION
xx1300002448
xx1300002456
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
2
CAUTION
xx1400000405
xx1400000406
Action Note
7 Remove the bracket inside the base by removing
the screws.
xx1400000407
xx1400000411
Action Note
1
CAUTION
Action Note
3 Remove the M2 variseal sealing.
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.
xx1400000780
xx1400000270
Action Note
1
CAUTION
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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection type Clean
Room
Apply a little grease to the sealing when
replacing the radial sealing and wipe clean
after the replacement.
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
Action Note
6 Fit a new M2 variseal sealing in its groove
in the base.
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.
CAUTION
xx1400000780
Note
Action Note
2 For robots with protection class IP67 (option Gasket for rear base cover:
287-10) 3HAC058566-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket on the base cover.
Replace if damaged.
xx1400000741
xx1300002448
Note
xx1400000480
Note
Cabling with bottom interface, 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 Clean the joints that have been opened. See Cut
the paint or surface on the robot before replacing
parts on page 144
2 Insert the cable package in and up through the
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
5 For robots with protection class IP67 (option Gasket for rear base cover:
287-10) 3HAC058566-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the base cover.
Replace if damaged.
xx1400000413
Action Note
8 Refit the base cover. Screws: 3HAB3409-212 (M4x16).
Tightening torque: 4 Nm.
xx1400000405
Note
xx1400000480
Note
Action Note
1 Clean the joints that have been opened. See Cut
the paint or surface on the robot before replacing
parts on page 144
2 Check the axis-1 sealing ring. Axis-1 sealing ring: 3HAC044676-
Replace if damaged. 001 / 3HAC058568-001 i
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
For robots with protection type Foundry Plus
(option 287-3)
On axis-1 sealing ring version 3HAC058568-001:
Check the gasket on the axis-1 sealing ring.
(See Spare part versions for the axis-1 sealing
ring on IP40/IP67 robots on page 803.)
Replace if damaged. xx1400000458
xx1600001149
xx1600001150
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
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.
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
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
xx1600000170
Action Note
4 Fit the guide pins to the drive unit. Guide pin for axis-1 gear unit:
3HAC049703-001
xx1300002566
CAUTION
xx1300002567
Note
Action Note
7 Remove the guide pins and refit the remain-
ing attachment screws and washers.
xx1300000523
xx1400000425
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).
Tightening torque: 1.5 Nm.
xx1300000467
Note
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 Reconnect the connectors and secure the
connectors to the bracket with cable straps.
xx1300002496
xx1300000470
xx1400000404
Action Note
4 For robots with protection class IP67 O-ring: 3HAB3772-86
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the O-ring.
Replace if damaged.
xx1400000412
xx1300000469
xx1400000403
Note
Action Note
6 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
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.
xx1400000476
3 For robots with protection class IP67 (option Gasket of plastic plate:
287-10) 3HAC044894-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing plastic
plate.
Replace if damaged.
xx1400000457
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
Action Note
6 For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641-
287-10) 004
For robots with protection type Foundry Plus
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
xx1400000454
Action Note
7 For robots with protection class IP67 (option Radial sealing with dust lip:
287-10) 3HAB3701-41
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the radial sealing.
Replace if damaged.
Note
xx1400000753
Tip
9 Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm.
xx1400000020
Action Note
10 Refit the cable housing with the screws. Screws: 3HAB3409-236 (M4x10).
Tightening torque: 3 Nm.
xx1300002435
Note
xx1400000481
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
xx1400000021
xx1300002432
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
Action Note
18 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056726-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000424
Action Note
21 Refit the cable housing cover. Cable housing cover of the swing:
Replace if damaged. 3HAC059678-001
: 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).
Tightening torque: 1.5 Nm.
xx1300002431
Note
22 For robots with protection type Foundry Plus Protection plug for lifting holes:
(option 287-3) 3HAC4836-24
Check the protection plugs for lifting holes.
Replace if damaged.
xx1600001151
Action Note
23 For robots with with protection type Clean Room Swing sealing plug:3HAC053687-
For robots with food grade lubrication 001
Refit the swing sealing plug.
Follow the procedure specified in Refitting the
swing sealing plug on page 151.
xx1600000205
24 Refit the lower arm bracket to the cable package. Tightening torque: 1.5 Nm.
CAUTION
xx1300002430
Note
Action Note
3 For robots with protection class IP67 (option Gasket on EIB/SMB cover:
287-10) 3HAC056728-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the EIB/SMB cover gasket.
Replace if damaged.
xx1400000475
WARNING
5 Valid for IRB 1200 (no type specified) and IRB xx1300002428
1200 Type A
Connect the lugs to the EIB/SMB cover.
6 Valid for IRB 1200 Type B
Connect the connectors to the SMB unit.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING
xx1700000005
Action Note
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
Action Note
9 Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm.
arm.
xx1300002426
Note
xx1400000483
Action Note
3 Guide the cable package into the upper arm,
through the housing.
Note
4 Refit the bracket to the sheet with two screws. Tightening torque: 1.5 Nm.
CAUTION
xx1300002424
5 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm.
xx1300002423
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).
Tightening torque: 4 Nm.
Tip
xx1300002422
xx1400001133
xx1300002420
Action Note
9 Apply grease to the cable package, cover all
moving area of the package.
xx1400000754
Note
CAUTION
xx1300002371
Action Note
2 Secure the connectors to the motor with a cable
strap.
xx1300002494
Tip
xx1300002399
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
Action Note
5 For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
xx1600000214
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
Action Note
10 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056724-001
For robots with protection type Foundry Plus PTFE film on cable housing cover:
(option 287-3) 3HAC044660-001
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000048
Action Note
13 Refit the cable housing cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm
xx1300002400
Note
Note
xx1400000738
Action Note
2 If equipped, reconnect the CP/CS connector.
For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
CAUTION
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 Gasket for tubular cable housing cover:
(option 287-10) 3HAC056707-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
Action Note
3 Refit the cover to the cable housing. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm.
xx1300002389
Note
Note
Concluding procedure
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
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the gasket.
Replace if damaged.
xx1400000477
Action Note
2 Refit the upper arm housing cover with the Screws: 3HAB3409-207 (M3x8).
screws. Tightening torque: 1.5 Nm.
CAUTION
xx1300000456
Note
xx1600000215
Note
4.5.2 Replacing the swing spare parts (swing, axis-2 radial sealing)
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
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.
Required consumables
Consumable Art. no. Note
Cable straps -
Locking liquid 3HAB7116-1 Loctite 243
Cleaning agent - Loctite 7063
Flange sealing 12340011-116 Loctite 574
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.
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
Action Note
2 Jog all axes to zero position.
xx1300002581
3
DANGER
4
CAUTION
xx1300002389
Tip
CAUTION
Action Note
1
DANGER
CAUTION
xx1300002390
CAUTION
2
CAUTION
xx1300002400
Action Note
4 Remove the plate.
xx1300002413
5 Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 :
disconnect them.
xx1300002412
xx1400001471
Action Note
6 Remove the small cover of the housing.
xx1300002398
xx1300002399
2
CAUTION
Action Note
3 Remove the cover from the upper arm housing.
CAUTION
xx1300000456
xx1300002494
Tip
xx1300002495
Action Note
2 Pull out the axis-3 motor connectors from the
housing and disconnect them.
CAUTION
xx1300002420
CAUTION
xx1300002422
xx1300002421
Action Note
4 Remove the screws that fasten the fix sheet to
the motor.
xx1300002423
CAUTION
xx1300002424
2
ELECTROSTATIC DISCHARGE (ESD)
3
CAUTION
Action Note
4 Remove the EIB/SMB cover attachment screws
on the lower arm and carefully open the cover.
CAUTION
CAUTION
xx1300002428
xx1700000004
Action Note
8 Valid for IRB 1200 Type B
Disconnect the connectors on the SMB unit.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
Remove the EIB/SMB cover completely from the
lower arm.
xx1700000005
2
CAUTION
xx1300002426
Action Note
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
xx1400001130
xx1600000205
xx1300002431
Action Note
9 Cut the cable straps.
xx1400001528
xx1300002432
CAUTION
xx1300002433
Action Note
12 Disconnect the motor connectors.
• R2.ME2
• R2.MP2
xx1300002434
xx1300002435
xx1400000020
Tip
Action Note
16 Loosen the plastic plate from the cable housing
in order to facilitate continued removal of the cable
package .
xx1400000023
Note
Action Note
1
DANGER
2
CAUTION
Action Note
3 Remove the swing cover.
xx1300002551
WARNING
xx1300002552
Action Note
5 Fit guide pins to the gearbox. Guide pin for axis-2 gear unit:
3HAC049704-001
Always use three guide pins together!
xx1300002563
Tip
xx1300002553
2
CAUTION
Action Note
3 Remove the swing top cover by removing the
screws.
Tip
xx1400000447
xx1400000448
CAUTION
xx1400000449
Action Note
6 Remove the axis-1 sealing ring from the swing
and carefully run the cabling out from the swing.
xx1400000455
2
CAUTION
Action Note
3 Remove the axis-2 radial sealing from the cable
housing.
xx1400000450
xx1600000053
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
For robots with protection type Foundry Plus
(option 287-3)
On axis-1 sealing ring version 3HAC058568-001:
Check the gasket on the axis-1 sealing ring.
Replace if damaged.
(See Spare part versions for the axis-1 sealing
ring on IP40/IP67 robots on page 803.) xx1400000458
xx1600001149
xx1600001150
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 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
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).
Tightening torque: 40 Nm.
xx1400000448
Note
Action Note
10 For robots with protection class IP67 (option Gasket on top swing cover:
287-10) 3HAC056696-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket.
Replace if damaged.
xx1400000425
11 Refit the swing top cover with the screws. Cover on top of swing:
Replace if damaged. 3HAC059679-001
: 3HAC056133-001 (used with pro-
tection type Clean Room)
Cover on top of swing, Clean Room
Cover on top of swing, food grade
lubrication
Screws: 3HAB3409-209 (M3x20).
Tightening torque: 1.5 Nm.
xx1400000447
Note
Note
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.
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
with food grade lubrication.
Action Note
1 Clean the joints that have been opened. See Cut
the paint or surface on the robot before replacing
parts on page 144
2 For robots with protection type Clean Room
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
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
xx1400000452
Note
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Check the o-ring. O-ring: 3HAC048939-001
Replace if damaged.
xx1300002556
Action Note
3 Remove residual locking liquid and other
pollutants with cleaning agent Loctite 7063.
Apply flange sealing Loctite 574 to the cyl-
indrical surface in the swing.
Note
xx1400001403
4 Fit guide pins to the gearbox. Guide pin for axis-2 gear unit:
3HAC049704-001
xx1300002562
Action Note
5 For robots with protection class IP67 M2 variseal sealing: 3HAC044641-003
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
xx1400000453
xx1300002563
Action Note
7 Refit the lower arm screws and washers, Screws: 3HAB3409-51 (M10x30).
using locking liquid Loctite 243.
Secure the screws but do not tighten yet.
xx1300002564
Note
xx1300002565
Action Note
10 For robots with protection class IP67 Gasket on swing cover: 3HAC056727-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the swing cover gasket.
Replace if damaged.
xx1400000007
xx1300002551
Action Note
12 For robots with protection type Foundry Protection plug for lifting holes:
Plus (option 287-3) 3HAC4836-24
Check the protection plugs for lifting holes.
Replace if damaged.
xx1600001151
xx1600000217
xx1600001154
Note
xx1400000476
3 For robots with protection class IP67 (option Gasket of plastic plate:
287-10) 3HAC044894-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing plastic
plate.
Replace if damaged.
xx1400000457
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
Action Note
6 For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641-
287-10) 004
For robots with protection type Foundry Plus
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
xx1400000454
Action Note
7 For robots with protection class IP67 (option Radial sealing with dust lip:
287-10) 3HAB3701-41
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the radial sealing.
Replace if damaged.
Note
xx1400000753
Tip
9 Refit the axis-2 sealing ring with the screws. Tightening torque: 1.5 Nm.
xx1400000020
Action Note
10 Refit the cable housing with the screws. Screws: 3HAB3409-236 (M4x10).
Tightening torque: 3 Nm.
xx1300002435
Note
xx1400000481
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
xx1400000021
xx1300002432
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
Action Note
18 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056726-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000424
Action Note
21 Refit the cable housing cover. Cable housing cover of the swing:
Replace if damaged. 3HAC059678-001
: 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).
Tightening torque: 1.5 Nm.
xx1300002431
Note
22 For robots with protection type Foundry Plus Protection plug for lifting holes:
(option 287-3) 3HAC4836-24
Check the protection plugs for lifting holes.
Replace if damaged.
xx1600001151
Action Note
23 For robots with with protection type Clean Room Swing sealing plug:3HAC053687-
For robots with food grade lubrication 001
Refit the swing sealing plug.
Follow the procedure specified in Refitting the
swing sealing plug on page 151.
xx1600000205
24 Refit the lower arm bracket to the cable package. Tightening torque: 1.5 Nm.
CAUTION
xx1300002430
Note
Action Note
3 For robots with protection class IP67 (option Gasket on EIB/SMB cover:
287-10) 3HAC056728-001
For robots with protection type Foundry Plus
(option 287-3)
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the EIB/SMB cover gasket.
Replace if damaged.
xx1400000475
WARNING
5 Valid for IRB 1200 (no type specified) and IRB xx1300002428
1200 Type A
Connect the lugs to the EIB/SMB cover.
6 Valid for IRB 1200 Type B
Connect the connectors to the SMB unit.
• R1.ME1,2,4,5
• R1.ME3,6
• R2.SMB
WARNING
xx1700000005
Action Note
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
Action Note
9 Refit the fix sheet attachment screws in the lower Tightening torque: 1.5 Nm.
arm.
xx1300002426
Note
xx1400000483
Action Note
3 Guide the cable package into the upper arm,
through the housing.
Note
4 Refit the bracket to the sheet with two screws. Tightening torque: 1.5 Nm.
CAUTION
xx1300002424
5 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm.
xx1300002423
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).
Tightening torque: 4 Nm.
Tip
xx1300002422
xx1400001133
xx1300002420
Action Note
9 Apply grease to the cable package, cover all
moving area of the package.
xx1400000754
Note
CAUTION
xx1300002371
Action Note
2 Secure the connectors to the motor with a cable
strap.
xx1300002494
Tip
xx1300002399
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
Action Note
5 For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
xx1600000214
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
Action Note
10 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056724-001
For robots with protection type Foundry Plus PTFE film on cable housing cover:
(option 287-3) 3HAC044660-001
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000048
Action Note
13 Refit the cable housing cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm
xx1300002400
Note
Note
xx1400000738
Action Note
2 If equipped, reconnect the CP/CS connector.
For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
CAUTION
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 Gasket for tubular cable housing cover:
(option 287-10) 3HAC056707-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
Action Note
3 Refit the cover to the cable housing. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm.
xx1300002389
Note
Note
Concluding procedure
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
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the gasket.
Replace if damaged.
xx1400000477
Action Note
2 Refit the upper arm housing cover with the Screws: 3HAB3409-207 (M3x8).
screws. Tightening torque: 1.5 Nm.
CAUTION
xx1300000456
Note
xx1600000215
Note
Action Note
6
DANGER
xx1400000391
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.
Action Note
1 Jog the robot to a position where the
mechanical stop is most easily accessed.
2
DANGER
Action Note
1
DANGER
Action Note
7
DANGER
xx1300002547
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.
Required consumables
Consumable Art. no. Note
Cable straps -
Cleaning agent - Loctite 7063
Flange sealing 12340011-116 Loctite 574
Locking liquid 3HAB7116-1 Loctite 243
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.
The gear is pre-filled at delivery
but grease may need to be added
depending on the actual condi-
tion.
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.
xx1300002581
3
DANGER
4
CAUTION
Action Note
1
DANGER
Action Note
2
CAUTION
xx1600000205
xx1300002431
Action Note
5 Cut the cable straps.
xx1400001528
xx1300002432
xx1300002434
Action Note
8 Pull out the cable harness slightly from the
lower arm housing.
Note
xx1300002548
CAUTION
xx1300002549
Action Note
1
DANGER
Action Note
2
CAUTION
xx1300002551
WARNING
xx1300002552
Action Note
5 Fit guide pins to the gearbox. Guide pin for axis-2 gear unit:
3HAC049704-001
Always use three guide pins together!
xx1300002563
Tip
xx1300002553
Action Note
1
DANGER
2
CAUTION
Action Note
3
CAUTION
WARNING
xx1400000008
xx1300002555
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
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).
3 For robots with protection class IP67
(option 287-10)
For robots with protection type Foundry
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 lower arm.
Note
xx1400000006
Action Note
4 Carefully insert the complete drive unit.
Note
xx1300002580
xx1400000795
xx1300002554
Note
Action Note
7 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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Check the o-ring. O-ring: 3HAC048939-001
Replace if damaged.
xx1300002556
Note
xx1400001403
Action Note
4 Fit guide pins to the gearbox. Guide pin for axis-2 gear unit:
3HAC049704-001
xx1300002562
CAUTION
xx1400000453
xx1300002563
Action Note
7 Refit the lower arm screws and washers, Screws: 3HAB3409-51 (M10x30).
using locking liquid Loctite 243.
Secure the screws but do not tighten yet.
xx1300002564
Note
xx1300002565
Action Note
10 For robots with protection class IP67 Gasket on swing cover: 3HAC056727-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the swing cover gasket.
Replace if damaged.
xx1400000007
xx1300002551
Action Note
12 For robots with protection type Foundry Protection plug for lifting holes:
Plus (option 287-3) 3HAC4836-24
Check the protection plugs for lifting holes.
Replace if damaged.
xx1600001151
xx1600000217
xx1600001154
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Refit the cable housing to the swing with Tightening torque: 3 Nm.
the screws.
xx1300002549
xx1300002548
Action Note
4 Reconnect the motor connectors.
• R2.ME2
• R2.MP2
xx1300002434
xx1300002432
xx1400001529
Action Note
7 For robots with protection class IP67 Gasket on cable housing cover:
(option 287-10) 3HAC056726-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the gasket of the cable housing
cover.
Replace if damaged.
8 Check the PTFE film. PTFE film on cable housing cover:
Replace if damaged. 3HAC044660-001
xx1300002431
Note
Action Note
11 For robots with with protection type Clean Swing sealing plug:3HAC053687-001
Room
For robots with food grade lubrication
Refit the swing sealing plug.
Follow the procedure specified in Refitting
the swing sealing plug on page 151.
xx1600000205
Note
Concluding procedure
Action Note
1 Remove the lifting slings from the robot.
2 Recalibrate the robot. Calibration is detailed in section Calibration
on page 737.
3
CAUTION
Note
4
DANGER
xx1300002527
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.
Required consumables
Consumable Art. no. Note
Cleaning agent - Isopropanol
Locking liquid 3HAB7116-1 Loctite 243
Flange sealing 12340011-116 Loctite 574
For robots with protection class
IP67 (option 287-10)
For robots with protection type
Foundry Plus (option 287-3)
Sealant 3HAC026759-001 Sikaflex 521FC
For robots with protection type
Clean Room
Harmonic grease 4B No. 2 3HAC037302-001 Total amount: 32 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: 32 g.
Used to lubricate the gearbox of
robots with food grade lubrica-
tion.
The gear is pre-filled at delivery
but grease may need to be added
depending on the actual condi-
tion.
Action Note
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.
xx1300002581
3
DANGER
Action Note
4
CAUTION
xx1300002400
xx1300002413
Action Note
2 Pull out the axis-3 motor connectors from the
housing and disconnect them.
CAUTION
xx1300002420
Action Note
1
DANGER
2
CAUTION
xx1300002421
Action Note
4 Remove the screws that fasten the fix sheet
to the motor.
xx1300002423
Note
xx1300002530
xx1400000785
Action Note
1
DANGER
2
CAUTION
xx1300002528
4
CAUTION
Action Note
6 Remove the upper arm screws.
WARNING
xx1300002531
7 Fit guide pins to the upper arm. Guide pin for upper arm: 3HAC049705-001
Always use three guide pins together!
xx1400000771
xx1300002533
xx1300002532
CAUTION
xx1300002534
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
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).
Action Note
3 Check the o-ring for damage. Replace if O-ring: 3HAC048939-002
damaged.
xx1400000004
Note
Note
xx1300002534
Action Note
7 Refit the drive unit screws. Screws: 3HAB3409-214 (M4x40)
Tightening torque: 4.5 Nm
xx1300002532
Note
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Fit guide pins to the axis-3 gear unit. Guide pin for upper arm: 3HAC049705-001
Always use three guide pins together!
xx1400000027
Action Note
3 For robots with protection class IP67 M2 variseal sealing: 3HAC044641-005
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
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
Action Note
5 Remove the guide pins and refit the remain-
ing screws and washers.
xx1400000029
xx1400000047
Action Note
8 Refit the lower arm cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm.
xx1300002528
Note
9 For robots with protection class IP67 Gasket on lower arm cable housing:
(option 287-10) 3HAC044895-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the cable housing gasket.
Replace if damaged.
xx1400000414
Action Note
10 For robots with protection class IP67 M2 variseal sealing: 3HAC044641-006
(option 287-10) Radial sealing: 3HAC024865-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the axis-3 radial sealing and the M2
variseal sealing in the cable housing.
Replace if damaged.
Note
Note
xx1400000785
Action Note
12 For robots with protection type Clean
Room
Apply a string of the sealant Sikaflex 521FC
to the joint of the cable housing of the lower
arm.
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.
Note xx1600000218
xx1600001155
Note
Concluding procedure
Action Note
1 Refit the fix sheet to the motor. Tightening torque: 1.5 Nm.
xx1300002423
2 Refit the fix sheet to the inner plastic guide. Tightening torque: 1.5 Nm.
xx1300002421
xx1300002420
Action Note
4 Refit the plate. Tightening torque: 1.5 Nm.
xx1300002413
5 For robots with protection class IP67 Gasket on cable housing cover:
(option 287-10) 3HAC056724-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the gasket of the cable housing
cover.
Replace if damaged.
xx1400000048
Action Note
6 Check the PTFE film on the cable housing PTFE film on cable housing cover:
cover. 3HAC044660-001
Replace if damaged.
7 Apply grease to the inner surface of the
cable housing cover and the PTFE film
surface.
8 Refit the cable housing cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm
xx1300002400
Note
9
CAUTION
Note
Action Note
11
DANGER
xx1300002462
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.
Required consumables
Consumable Art. no. Note
Cable straps -
Cleaning agent - Loctite 7063
Flange sealing 12340011-116 Loctite 574
For robots with protection class
IP67 (option 287-10)
For robots with protection type
Foundry Plus (option 287-3)
Locking liquid 3HAB7116-1 Loctite 243
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.
Action Note
2 Jog all axes to zero position.
xx1300002581
3
DANGER
2
CAUTION
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)
For robots with protection type
Note Foundry Plus (option 287-3)
xx1600001148
Tip
CAUTION
Action Note
1
DANGER
2
CAUTION
xx1300002350
xx1300002351
xx1300002390
Action Note
6 Remove the screws and pull out the motor.
xx1300002352
2
CAUTION
xx1300002353
xx1300002355
Action Note
5 Remove the connector plate attachment screws.
xx1300002356
xx1300002357
xx1300002358
Action Note
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
xx1300002611
2
CAUTION
CAUTION
xx1300000456
Action Note
4 Cut the strap that holds the connectors.
xx1300002494
Tip
xx1300002495
2
CAUTION
Action Note
3 Remove the cable housing cover.
xx1300002400
xx1300002413
Action Note
5 Pull out the FPC connectors from the housing and Cable layout in IRB 1200-7/0.7 :
disconnect them.
xx1300002412
xx1400001471
xx1300002398
Action Note
7 Disconnect the remaining FPC connectors.
xx1300002399
Action Note
1
DANGER
2
CAUTION
xx1300002524
Action Note
4 Remove the motor screws and washers
and carefully lift out the motor and the pul-
ley.
xx1300002522
Action Note
1
DANGER
2
3 Remove the plastic protection plate by re-
moving its screws.
xx1400000797
xx1300002373
xx1600000262
xx1300002372
xx1300002374
Action Note
1
DANGER
2
3 Remove the screws and washers.
xx1300002376
xx1400002400
xx1300002387
Action Note
1
DANGER
2
3 Remove the gear attachment screws.
xx1300002378
xx1300002379
Action Note
5 Remove the pulley from the gear by remov-
ing its attachment screws.
xx1300002380
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Refit the pulley to the gear and secure with Screws: 3HAB3409-209 (M3x20).
its attachment screws. Tightening torque: 1.1 Nm.
xx1300002380
Note
Action Note
3 Refit the gear to the housing.
xx1300002379
xx1300002378
Note
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
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
xx1300002377
xx1300002376
Note
Action Note
5 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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 M2 variseal sealing: 3HAC044641-007
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
xx1300002418
Action Note
3 For robots with protection class IP67 Radial sealing with dust lip: 3HAB3701-48
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the radial sealing.
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
xx1400000436
Action Note
8 Screw the screws, little by little, to press
the sealing into place.
xx1400000437
Note
Note
xx1300002613
Action Note
3 For robots with protection type Clean Room
For robots with protection type Foundry Plus
Make sure the four cavities are fully filled with
glue. If not, fill glue again before the refitting.
xx1600000216
CAUTION
Note
xx1300002372
6 For robots with protection type Foundry Plus Screw sealing plug: 3HAC053685-
(option 287-3) 001
For robots with protection type Clean Room
For robots with food grade lubrication
Press in screw sealing plugs to cover the screws.
xx1600000263
Action Note
7 Fit and secure the axis-4 FPC unit screws. Tightening torque: 0.3 Nm.
xx1300002373
Note
Action Note
1
DANGER
xx1400000797
Action Note
6 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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Check that:
• all assembly surfaces are clean and
undamaged.
• the motor is clean and undamaged.
3 Fit the timing belt to the motor pulley.
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
xx1300002525
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.
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
Tip
xx1300002399
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
Action Note
5 For robots with protection class IP67 (option
287-10)
For robots with protection type Foundry Plus
(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
xx1600000214
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
Action Note
10 For robots with protection class IP67 (option Gasket on cable housing cover:
287-10) 3HAC056724-001
For robots with protection type Foundry Plus PTFE film on cable housing cover:
(option 287-3) 3HAC044660-001
For robots with with protection type Clean Room
For robots with food grade lubrication
Check the gasket of the cable housing cover.
Replace if damaged.
xx1400000048
Action Note
13 Refit the cable housing cover. Screws: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm
xx1300002400
Note
Note
CAUTION
xx1300002371
Action Note
2 Secure the connectors to the motor with a cable
strap.
xx1300002494
CAUTION xx1300002359
xx1300002611
Action Note
3 Refit the washer while at the same time putting Washer: 3HAC044869-001
the cables through its center.
Replace washer, if damaged.
xx1400000001
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
Action Note
7 Put the cables through the plate hole and refit the Tightening torque: 0.3 Nm.
plate.
xx1300002356
CAUTION
xx1300002355
xx1300002353
Note
CAUTION
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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Refit the timing belt on the pulley.
xx1300002351
Action Note
4 Secure the motor with its attachment
screws.
xx1300002350
Note
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
CAUTION
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 Gasket for tubular cover: 3HAC058822-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
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
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
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.
For robots with protection type Clean
Room
Remember to refit the extra two screws and
washers to the tubular cover.
xx1300002349
xx1600001153
Note
Note
Concluding procedure
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
For robots with with protection type Clean Room
For robots with food grade lubrication
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.
xx1300000456
Note
xx1600000215
4
CAUTION
Note
Action Note
5 Recalibrate the robot. Calibration is detailed in section
Calibration on page 737.
6
DANGER
Location of motor
The axis-4 motor is located as shown in the figure.
xx1300002474
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.
Required consumables
Consumable Art. no. Note
Cleaning agent - Isopropanol
Cable straps -
Sealant 3HAC026759-001 Sikaflex 521FC
For robots with protection type
Clean Room
Action Note
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.
xx1300002581
3
DANGER
2
CAUTION
CAUTION
xx1300000456
xx1300002494
Action Note
5 Disconnect the motor connectors.
Tip
xx1300002495
Action Note
1
DANGER
2
CAUTION
xx1300002524
Action Note
4 Remove the motor screws and washers
and carefully lift out the motor and the pul-
ley.
xx1300002522
Action Note
1
DANGER
2
CAUTION
xx1300002523
Action Note
1 Clean the joints that have been opened. See Cut
the paint or surface on the robot before replacing
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
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Check that:
• all assembly surfaces are clean and
undamaged.
• the motor is clean and undamaged.
3 Fit the timing belt to the motor pulley.
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
xx1300002525
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.
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
CAUTION
xx1300002371
xx1300002494
Concluding procedure
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
For robots with with protection type Clean
Room
For robots with food grade lubrication
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.
xx1300000456
Note
xx1600000215
Action Note
4
CAUTION
Note
xx1400000036
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.
Required consumables
Consumable Art. no. Note
Cleaning agent - Isopropanol
Cable straps -
Sealant 3HAC026759-001 Sikaflex 521FC
For robots with protection type
Clean Room
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.
Action Note
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
xx1300002581
3
DANGER
4
CAUTION
Action Note
5 Remove the lower arm cable housing cover.
xx1300002400
xx1300002389
xx1400002327
Action Note
2
CAUTION
CAUTION
xx1300000456
xx1300002494
Tip
xx1300002495
Action Note
1
DANGER
2
CAUTION
xx1300002524
xx1300002522
Action Note
1
DANGER
2
3 Remove the plastic protection plate by re-
moving its screws.
xx1400000797
Action Note
1
DANGER
Action Note
2 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
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
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Check that:
• all assembly surfaces are clean and
undamaged.
• the motor is clean and undamaged.
3 Fit the timing belt to the motor pulley.
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
xx1300002525
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.
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
CAUTION
xx1300002371
xx1300002494
xx1400002327
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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 For robots with protection class IP67 Gasket for tubular cable housing cover:
(option 287-10) 3HAC056707-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
xx1300002389
Note
Note
Concluding procedure
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
For robots with with protection type Clean
Room
For robots with food grade lubrication
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.
xx1300000456
Note
xx1600000215
Action Note
4 For robots with protection class IP67 Gasket on cable housing cover:
(option 287-10) 3HAC056724-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the gasket of the cable housing
cover.
Replace if damaged.
xx1400000048
5 Check the PTFE film on the cable housing PTFE film on cable housing cover:
cover. 3HAC044660-001
Replace if damaged.
6 Apply grease to the inner surface of the
cable housing cover and the PTFE film
surface.
Action Note
7 Refit the cable housing cover. Tightening torque: 3HAB3409-207 (M3x8).
Tightening torque: 1.5 Nm
xx1300002400
Note
8
CAUTION
Note
Location of motor
The axis-5 motor is located as shown in the figure.
xx1300002473
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.
Required consumables
Consumable Art. no. Note
Cleaning agent - Isopropanol
Locking liquid 3HAB7116-1 Loctite 243
For robots with protection class
IP67 (option 287-10)
For robots with protection type
Foundry Plus (option 287-3)
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.
xx1300002581
3
DANGER
2
CAUTION
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)
For robots with protection type
Note Foundry Plus (option 287-3)
xx1600001148
Tip
CAUTION
Action Note
1
DANGER
2
CAUTION
xx1300002350
xx1300002351
xx1300002390
Action Note
6 Remove the screws and pull out the motor.
xx1300002352
CAUTION
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
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 Refit the timing belt on the pulley.
xx1300002351
xx1300002350
Note
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
CAUTION
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 Gasket for tubular cover: 3HAC058822-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
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
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
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.
For robots with protection type Clean
Room
Remember to refit the extra two screws and
washers to the tubular cover.
xx1300002349
xx1600001153
Note
Note
Concluding procedure
Action Note
1
CAUTION
Note
xx1400000032
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.
Required consumables
Consumable Art. no. Note
Cleaning agent - Isopropanol
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.
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
Action Note
2 Jog all axes to zero position.
xx1300002581
3
DANGER
4
CAUTION
xx1400000033
Action Note
1
DANGER
xx1300002350
3
CAUTION
xx1300002351
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
Action Note
2 Refit the timing belt on the pulley.
xx1300002351
xx1300002350
Note
Concluding procedure
Action Note
1 For robots with protection class IP67 Gasket for tubular cover: 3HAC058822-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the gasket of the wrist cover.
Replace if damaged.
xx1400000034
Action Note
2 Refit the cover 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 type Foundry
Plus (option 287-3)
Apply locking liquid Loctite 243 to the two
front screws on the left hand side cover,
encircled in the figure.
xx1400000033
Note
3
CAUTION
Note
xx1300002467
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.
Required consumables
Consumable Art. no. Note
Cleaning agent - Loctite 7063
Locking liquid 3HAB7116-1 Loctite 243
Flange sealing 12340011-116 Loctite 574
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.
Action Note
1 Decide which calibration routine to use,
and take actions accordingly prior to begin-
ning the repair procedure.
2 Jog all axes to zero position.
xx1300002581
3
DANGER
Action Note
2
CAUTION
3 Remove the covers on each side of the wrist by For robots with protection class
removing their screws. IP67 (option 287-10)
For robots with protection type
Note Foundry Plus (option 287-3)
xx1600001148
Action Note
2 Snap loose and disconnect the axis-5 FPC con-
nectors.
xx1300002390
xx1300002391
Note
xx1300002393
Action Note
3 Remove the sleeve by screwing in two of the
screws into the press out holes to force the sleeve
out.
xx1300002582
xx1300002394
xx1300002395
2
CAUTION
Action Note
3 Loosen the attachment screws of the axis-5 motor
so that the motor can slide sideways.
xx1300002350
xx1300002351
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
xx1300002470
xx1600001126
3 For robots with protection class IP67 (option M2 variseal sealing: 3HAC044641-
287-10) 008
For robots with protection type Foundry Plus
(option 287-3)
Check the sealing.
Replace if damaged.
CAUTION
xx1300002493
Note
Action Note
5 Fit guide pins to the axis-5 gearbox. Guide pin for tilt unit (axis 5):
3HAC049706-001
xx1300002568
xx1600000219
xx1600000220
Action Note
7 Refit the drive unit and secure with the screws Attachment screws: 3HAB3409-236
and washers. (M4x10).
Secure the screws but do not tighten yet.
Note
xx1300002569
Note
xx1300002570
Note
Action Note
1
WARNING
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
xx1300002394
Note
xx1300002609
Action Note
6 Refit the sleeve and secure with screws. Sleeve: 3HAC044661-001
Replace if damaged. Tightening torque: 1.5 Nm.
xx1300002393
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Check the sealing. M2 variseal sealing: 3HAC044641-009
Replace if damaged.
CAUTION
xx1300002396
Action Note
3 For robots with protection class IP67 Radial sealing: 3HAB3701-42
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the radial sealing.
Replace if damaged, as described below.
If undamaged and properly seated, skip to
the next procedure table.
xx1300002608
xx1400000485
Action Note
8 Screw the screws, little by little, to press
the sealing into place.
xx1400000486
Note
xx1300002610
Note
Action Note
3 Refit the tubular cable housing with the screws. Tightening torque: 1.5 Nm.
Tubular cable housing:
3HAC059695-001
: 3HAC056143-001 (used with pro-
tection type Clean Room)
Tubular cable housing, Clean
Room
Tubular cable housing, food grade
lubrication
xx1300002392
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Refit the timing belt on the pulley.
xx1300002351
Action Note
4 Secure the motor with its attachment
screws.
xx1300002350
Note
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 Refit the connector plate and secure with Tightening torque: 0.3 Nm.
the M3 screws.
xx1400001401
xx1400001402
Action Note
4 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
Action Note
1 Connect the axis-5 FPC connectors and
snap them to their holders.
CAUTION
xx1300002390
Action Note
1 Clean the joints that have been opened.
See Cut the paint or surface on the robot
before replacing parts on page 144
2 For robots with protection class IP67 Gasket for tubular cover: 3HAC058822-001
(option 287-10)
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cover gasket.
Replace if damaged.
xx1400000034
Action Note
3 For robots with protection class IP67 Gasket for tubular cable housing cover:
(option 287-10) 3HAC056707-001
For robots with protection type Foundry
Plus (option 287-3)
For robots with with protection type Clean
Room
For robots with food grade lubrication
Check the tubular cable housing cover
gasket.
Replace if damaged.
xx1400000345
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.
For robots with protection type Clean
Room
Remember to refit the extra two screws and
washers to the tubular cover.
xx1300002349
xx1600001153
Note
Note
Concluding procedure
Action Note
1
CAUTION
Note
5 Calibration
5.1 Introduction to calibration
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.
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
xx0400001197
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.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 816.
When to calibrate
The system must be calibrated if any of the following situations occur.
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
xx1400000402
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.
(C)
(D)
(E)
(F)
(B)
(A)
xx1300000365
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.
xx1500000942
Action
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943
xx1500000944
Action
4 A screen is displayed, tap Rev. Counters.
en0400000771
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.
• The axis position is stored in RobotWare with an active choice from the
operator.
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.
Validation
In the mentioned routines, it is also possible to validate the calibration data.
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
xx1500001914
A Tube insert
B Plastic protection
C Steel spring ring
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.
xx1600001142
A Outer diameter
xx1600001035
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.
Spare part Article number Note
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
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.
Required consumables
Consumable Article number Note
Clean cloth -
Spare parts
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.
Note
xx1500000942
xx1500000943
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.
xx1600001277 xx1600001276
xx1600001275 xx1600001274
Axis 5 Axis 6
Make sure to orient the tool flange calibration
tool correctly.
xx1600001273
xx1600001272
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
Action Note
1 SafeMove generates the message "Safety control-
ler not synchronized".
xx1500002480
Action Note
1 SafeMove generates the message "Unsynchron-
ized speed exceeded" while saving robot data.
xx1500002481
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
After calibration
Action Note
1 Check the o-ring on the plug.
Replace the plug with new spare part, if missing
or damaged.
xx1600001143
xx1600001144
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
xx1400001209
Required equipment
Equipment Art. no. Note
Calibration toolkit, manual calibra- 3HAC051256-001 Includes calibration tools, pins
tion and attachment screws for
manual calibration method. i
Required consumables
Equipment Art. no. Note
Cleaning agent - Isopropanol
Calibrating axis 1
Moving the robot to calibration position
Action Note
1 Jog all axes to zero position.
2 Remove the axis-1 mechanical stop pin.
xx1400000392
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
xx1400001134
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
xx1400001099
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
en0400001127
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.
xx1400001092
4 Remove the axis-1 calibration pin from the swing Protection plug: 3HAC051199-001
and refit the protection plug.
xx1400001134
xx1400000392
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.
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.
Calibrating axis 2
Moving the robot to calibration position
Action Note
1 Jog all axes to zero position.
2
DANGER
3 Release the brakes and manually rotate axis 2 How to release the brakes is de-
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.
When the axis is in position, release the brake
release button to activate the brakes again.
xx1400001201
Action Note
3 Tap to select the mechanical unit and then tap Calib. Parameters.
en0400001127
Action Note
2 Jog axis 2 to zero degree using the FlexPendant.
3 Check that the synchronization marks on axis 2
are aligned with eachother.
Are they aligned within the tolerances?
• If yes, the calibration is verified OK.
• If no, redo the fine calibration procedure.
xx1400001093
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.
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.
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
Moving the robot to calibration position
Action Note
1 Jog all axes to zero position.
2
DANGER
Action Note
3 Release the brakes and manually rotate axis 3 How to release the brakes is de-
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.
When the axis is in position, release the brake
release button to activate the brakes again.
xx1400001204
Action Note
3 Tap to select the mechanical unit and then tap Calib. Parameters.
en0400001127
Action Note
2 Jog axis 3 to zero degree using the FlexPendant.
3 Check that the synchronization marks on axis 3
are aligned with eachother.
Are they aligned within the tolerances?
• If yes, the calibration is verified OK.
• If no, redo the fine calibration procedure.
xx1400001094
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.
xx1400001207
Required equipment
Equipment Art. no. Note
Calibration toolkit, manual calibra- 3HAC051256-001 Includes calibration tools, pins
tion and attachment 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.
Required consumables
Equipment Art. no. Note
Cleaning agent - Isopropanol
Calibrating axis 4
Moving the robot to calibration position
Action Note
1 Jog all axes to zero position.
Rotate axis 4 some degrees toward positive direc-
tion to avoid interference between the calibration
tools when fitting them.
Action Note
2
DANGER
xx1400001205
xx1400001208
Tip
Action Note
7 Fit the conical screw to the calibration tool. Conical screw M3 (3HAC055410-
001, 1 pcs)
Tightening torque: 1 Nm
xx1500001608
xx1400001117
11 Release the brakes and manually rotate axis 4 How to release the brakes is de-
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.
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.
xx1400001207
en0400001127
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.
xx1400001095
xx1400001205
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.
xx1400001206
Required equipment
Equipment Art. no. Note
Calibration toolkit, manual calibra- 3HAC051256-001 Includes calibration tools, pins
tion and attachment 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.
Required consumables
Equipment Art. no. Note
Cleaning agent - Isopropanol
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
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.
When doing this, pay attention to robot pose in
order to avoid arm collision.
When the axis is in position, release the brake
release button to activate the brakes again.
xx1400001206
en0400001127
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.
xx1400001096
xx1400001097
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.
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
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.
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.
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
DANGER
7 Robot description
7.1 Type A of IRB 1200
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.
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).
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.
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
xx1600000051
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
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
xx1600000053
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
7.3.3 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
xx1600000126
xx1600001039
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
xx1600001129
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
7.3.6 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
xx1600001118
8 Reference information
8.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.
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
Standard Description
EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
Standard Description
EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design
Other standards
Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
(option 429-1)
CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require-
(option 429-1) ments
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
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.
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.
• 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%!
Note
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
Note
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
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.
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
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
xx1400000542
Roundsling, 2 m
- Length: 2 m. Lifting capacity: 100 1 1 1
kg.
xx1400000535
xx1400000541
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)
xx1400000538
xx1400000539
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
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
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
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
Robots
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
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
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