ABB Robotics IRB 120 Guide

Product manual, spare parts
IRB 120

Trace back information:
Workspace R16-1 version a2
Checked in 2016-02-26
Skribenta version 4.6.209

Product manual, spare parts
IRB 120 - 3/0.6
IRB 120T - 3/0.6
IRC5
Document ID: 3HAC049098-001
Revision: C
© Copyright 2016 ABB. All rights reserved.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
© Copyright 2016 ABB. All rights reserved.
ABB AB
Robotics Products
Se-721 68 Västerås
Sweden

Table of contents
7Overview of this manual ...................................................................................................................
8Product documentation, IRC5 ..........................................................................................................
111 Spare part lists and illustrations
111.1 Spare parts - Axes 1 and 2 .................................................................................. 131.2 Spare parts - Axis 3 ........................................................................................... 151.3 Spare parts - Lower arm, side support ................................................................... 161.4 Spare parts - Upper arm unit ............................................................................... 181.5 Spare parts - Wrist unit ....................................................................................... 201.6 Spare parts - Cable harness ................................................................................ 211.7 Spare parts coating ...........................................................................................
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Table of contents

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Overview of this manual
About this manual
This manual contains spare parts for:
• IRB 120 and all its variants.
Usage
This manual shall be used as a complement to the product manual for IRB 120
during:
• maintenance work
• repair work.
Who should read this manual?
This manual is intended for:
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
ContentsChapter
Complete spare part list and complete list of robot
components shown in exploded views.
1 Spare part lists and illustrations
References
Document IDReference
3HAC035728-001Product manual - IRB 120
3HAC031408-003Circuit diagram - IRB 120
Revisions
DescriptionRevision
First edition-
This edition contains the following changes:
•Spare parts with color Graphite White are added to the spare part lists.
A
New spare part number for timing belts on axis-3 motor and axis-5 motor,
and also for battery pack.
B
This edition contains the following changes:
• Spare parts with food grade lubrication added.
• Minor corrections.
C
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© Copyright 2016 ABB. All rights reserved.
Overview of this manual

Product documentation, IRC5
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 listed can be ordered from ABB on a DVD. The documents listed
are valid for IRC5 robot systems.
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 exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe reference information for robotics
products.
•Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
•Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
•Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
•Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
•Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Continues on next page
8 Product manual, spare parts - IRB 120
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© Copyright 2016 ABB. All rights reserved.
Product documentation, IRC5

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, DVD with PC 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 trouble shooters.
The group of manuals includes (among others):
•Operating manual - Emergency safety information
•Operating manual - General safety information
•Operating manual - Getting started, IRC5 and RobotStudio
•Operating manual - Introduction to RAPID
•Operating manual - IRC5 with FlexPendant
•Operating manual - RobotStudio
•Operating manual - Trouble shooting IRC5, for the controller and manipulator.
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Product documentation, IRC5
Continued

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1 Spare part lists and illustrations
1.1 Spare parts - Axes 1 and 2
Spare parts axes 1-2
See Illustration axes 1-2 on page 12.
ColorProtection
type
Spare part num-
ber
DescriptionItem
ABB OrangeStandard3HAC049973-001Base with mechanical
stop
1
Graphite WhiteStandard3HAC049974-001Base with mechanical
stop
WhiteClean Room3HAC042144-001Base with mechanical
stop
--3HAC037281-001Rotational AC motor, in-
cluding gearbox (axes 1
& 2)
2
WhiteClean Room
(with food
grade lubrica-
tion)
3HAC057909-001Rotational AC motor,food
grade lubrication, includ-
ing gearbox (axes 1 & 2)
--3HAC031119-001Cable guide4
-Standard3HAC031694-001Mechanical stop pin6
-Clean Room3HAC042068-001Mechanical stop pin
--3HAA2166-23VK-cover9
ABB OrangeStandard3HAC049975-001Swing plate with mechan-
ical stop
10
Graphite WhiteStandard3HAC049976-001Swing plate with mechan-
ical stop
WhiteClean Room3HAC042146-001Swing plate with mechan-
ical stop
--3HAC031133-001Cable guide11
ABB OrangeStandard3HAC049977-001Swing housing with
mechanical stop
15
Graphite WhiteStandard3HAC049978-001Swing housing with
mechanical stop
WhiteClean Room3HAC042147-001Swing housing with
mechanical stop
--3HAC031871-001Damper16
--3HAC031134-001Cable guide17
--3HAC031135-001Cable guide18
--3HAC033060-001Calibration bracket20
Continues on next page
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1 Spare part lists and illustrations
1.1 Spare parts - Axes 1 and 2

Illustration axes 1-2
See Spare parts axes 1-2 on page 11.
15
1
6
16
11
24
20
2
10
9
17
18
xx0900000498
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1 Spare part lists and illustrations
1.1 Spare parts - Axes 1 and 2
Continued

1.2 Spare parts - Axis 3
Spare parts, axis 3
See Illustration, spare parts axis 3 on page 14.
ColorProtection
type
Spare part num-
ber
DescriptionItem
ABB OrangeStandard3HAC049979-001Lower arm with mechan-
ical stop i
1
Graphite WhiteStandard3HAC049980-001Lower arm with mechan-
ical stop i
WhiteClean Room3HAC042148-001Lower arm with mechan-
ical stop i
WhiteClean Room
(with food
grade lubrica-
tion)
3HAC057910-001Lower arm with mechan-
ical stop, food grade lub-
ricationii
--3HAC031904-001Motor unit with timing
belt wheel
2
ABB OrangeStandard3HAC049984-001Motor cover (axis 3)5
Graphite WhiteStandard3HAC049985-001Motor cover (axis 3)
WhiteClean Room3HAC042149-001Motor cover (axis 3)
--3HAC053109-001Timing belt10
-Standard3HAC031694-001
Mechanical stop pins iii
11
-Clean Room3HAC042068-001
Mechanical stop pins iii
--3HAC031871-001
Dampers iii
13
ABB OrangeStandard3HAC049986-001Lower arm cover6
Graphite WhiteStandard3HAC049987-001Lower arm cover
WhiteClean Room3HAC042151-001Lower arm cover
iIncluding axis-3 gearbox
ii Including axis-3 gearbox with food grade lubrication.
iii Shown in the enlargement in the figure.
Continues on next page
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1 Spare part lists and illustrations
1.2 Spare parts - Axis 3

Illustration, spare parts axis 3
See Spare parts, axis 3 on page 13.
xx0900000493
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1 Spare part lists and illustrations
1.2 Spare parts - Axis 3
Continued

1.3 Spare parts - Lower arm, side support
Spare parts, lower arm side support
See Illustration, Lower arm side support on page 15.
ColorProtection
type
Spare part num-
ber
DescriptionItem
ABB OrangeStandard3HAC049988-001Lower arm, side support1
Graphite WhiteStandard3HAC049989-001Lower arm, side support
WhiteClean Room3HAC042152-001Lower arm, side support
--3HAC031126-001Cable protection cover
axis 3
2
Illustration, Lower arm side support
See Spare parts, lower arm side support on page 15.
1
2
xx0900000500
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1 Spare part lists and illustrations
1.3 Spare parts - Lower arm, side support

1.4 Spare parts - Upper arm unit
Spare parts upper arm unit
See Illustration, upper arm unit on page 17.
ColorProtection
type
Spare part num-
ber
DescriptionItem
ABB OrangeStandard3HAC049992-001Upper arm with wrist,
mechanical i
A
Graphite WhiteStandard3HAC049993-001Upper arm with wrist,
mechanical i
WhiteClean Room3HAC042153-001Upper arm with wrist,
mechanical i
WhiteClean Room
(with food
grade lubrica-
tion)
3HAC057911-001Upper arm with wrist,
mechanical, food grade
lubricationii
--3HAC031121-001Arc shaft cover2
--3HAC031123-001Cable protector13
--3HAC031122-001Housing inner cover23
ABB OrangeStandard3HAC049990-001Housing cover7
Graphite WhiteStandard3HAC049991-001Housing cover
WhiteClean Room3HAC042154-001Housing cover
iIncludes axis-4 and axis-6 motors and gearboxes.
ii Includes axis-4 and axis-6 motors and gearboxes with food grade lubrication.
Continues on next page
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1 Spare part lists and illustrations
1.4 Spare parts - Upper arm unit

Illustration, upper arm unit
See Spare parts upper arm unit on page 16.
xx0900000544
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1 Spare part lists and illustrations
1.4 Spare parts - Upper arm unit
Continued

1.5 Spare parts - Wrist unit
Spare parts. wrist unit
See Illustration, spare parts wrist unit on page 19.
ColorProtection
type
Spare part num-
ber
DescriptionItem
--3HAC037303-001Motor unit with timing
belt pulley
7
--3HAC053110-001Timing belt8
ABB OrangeStandard3HAC049994-001Wrist housing, plastic(8)
Graphite WhiteStandard3HAC049995-001Wrist housing, plastic
WhiteClean Room3HAC042155-001Wrist housing, plastic
ABB OrangeStandard3HAC049996-001Wrist side cover(9)
Graphite WhiteStandard3HAC049997-001Wrist side cover
WhiteClean Room3HAC042156-001Wrist side cover
ABB OrangeStandard3HAC049998-001Tilt cover(10)
Graphite WhiteStandard3HAC049999-001Tilt cover
WhiteClean Room3HAC042157-001Tilt cover
See Spare parts -
Upper arm unit on
page 16.
Rotational AC motor with
gearbox i
16
iIncluded in the upper arm.
Continues on next page
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1 Spare part lists and illustrations
1.5 Spare parts - Wrist unit

Illustration, spare parts wrist unit
See Spare parts. wrist unit on page 18.
xx0900000551
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1 Spare part lists and illustrations
1.5 Spare parts - Wrist unit
Continued

1.6 Spare parts - Cable harness
Introduction
The spare parts in this section covers cable harness.
Spare part numberDescriptionItem
3HAC032095-001Cable harness main
3HAC032076-001Cable harness EIB
3HAC032296-001Cable harness CP/CS
3HAC032243-001EIB DSQC401
3HAC051036-001Battery pack
3HAC037038-001Connector set R1.CP/CS
3HAC037070-001Connector set R3.CP/CS
20 Product manual, spare parts - IRB 120
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1 Spare part lists and illustrations
1.6 Spare parts - Cable harness