ABB IRB 120 User manual

Product manual
Articulated robot
IRB 120 - 3/0.6

© Copyright 2009-2010 ABB. All rights reserved.
Product manual
IRB 120 - 3/0.6
M2004
Document ID: 3HAC035728-001
Revision: B

© Copyright 2009-2010 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
construedasany kindof guaranteeor warranty by ABBfor losses,damagesto 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, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
Copyright 2009-2010 ABB All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of Contents
33HAC035728-001 Revision: B
© Copyright 2009-2010 ABB. All rights reserved.
Overview of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Safety 15
1.1 Introduction to safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.1 Safety in the manipulator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.1 Safety risks during installation and service work on manipulators. . . . . . . . . . . . . . . . . . 17
1.2.2.2 CAUTION - Hot parts may cause burns! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.2.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.2.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.2.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2.6 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.3 Emergency release of the manipulator’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
1.2.3.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.4 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.4.1 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
1.3 Safety related instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.1 Safety signals in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.2 Safety symbols on the manipulator labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3.3 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.3.4 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3.5 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
1.3.6 WARNING - Safety risks during work with gearbox lubricants (oil or grease) . . . . . . . . . . . . . . 43
2 Installation and commissioning 45
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2.2 Working range and type of motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.2.3 Risk of tipping/Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3.1 Lifting the robot with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.3.3 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.3.4 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3.5 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3.6 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.4.2 Mechanically restricting the working range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.5.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.5.2 Customer connections on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Table of Contents
43HAC035728-001 Revision: B
© Copyright 2009-2010 ABB. All rights reserved.
3 Maintenance 73
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.2 Maintenance schedule and expected component life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.3.1 Inspection, robot cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.3.2 Inspecting mechanical stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.3.3 Inspecting dampers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.3.4 Inspecting timing belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.3.5 Inspecting plastic covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.4 Replacement/changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.4.1 Type of grease in gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.4.2 Replacing the battery pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.5 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.5.1 Cleaning, robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4 Repair 93
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2.1 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.3 Cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.3.1 Removing the cable harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.3.2 Refitting the cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.3.3 Replacing the Encoder Interface board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.4 Plastic covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.4.1 Replacing plastic covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.5 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.5.1 Replacing the upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.6 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.6.1 Replacing the lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.7 Motors and motors with gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.7.1 Replacing motor axis 1 with gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.7.2 Replacing motor axis 2, with gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.7.3 Replacing motor axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.7.4 Replacing motor axis 4, with gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.7.5 Replacing motor axis 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.7.6 Replacing motor axis 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.8.1 Replacing gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.8.2 Replacing gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.8.3 Replacing gearbox axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.8.4 Replacing gearbox axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.8.5 Replacing gearbox axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.8.6 Replacing gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5 Calibration 173
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.2 Calibrating axes 1 - 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.3 Synchronization marks axes 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Table of Contents
53HAC035728-001 Revision: B
© Copyright 2009-2010 ABB. All rights reserved.
6 Decommissioning 183
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6.2 Environmental information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
7 Reference information 185
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
7.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
7.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
7.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
7.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
8 Spare parts 195
8.1 Spare parts - Axes 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
8.2 Spare parts - Axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.3 Spare parts - Lower arm, side support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
8.4 Spare parts - Upper arm unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
8.5 Spare parts - Wrist unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8.6 Spare parts - Cable harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9 Circuit diagram 207
9.1 About circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Index 209

Table of Contents
63HAC035728-001 Revision: B
© Copyright 2009-2010 ABB. All rights reserved.

Overview of this manual
73HAC035728-001 Revision: B
© Copyright 2009-2010 ABB. All rights reserved.
Overview of this manual
About this manual This manual contains instructions for:
•mechanical and electrical installation of the robot
•maintenance of the robot
•mechanical and electrical repair of the robot.
Usage This manual should be used during:
•installation, from lifting the robot to its work site and securing it to the foundation, to
making it ready for operation
•maintenance work
•repair work and calibration.
Who should read this manual?
This manual is intended for:
•installation personnel
•maintenance personnel
•repair personnel.
Prerequisites 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.
Continues on next page

Overview of this manual
3HAC035728-001 Revision: B8
© Copyright 2009-2010 ABB. All rights reserved.
Organization of chapters
The manual is organized in the following chapters:
References
Chapter Contents
Safety Safety information that must be read through before performing
any installation or service work on the 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-
sioning Required information about lifting and installation of the robot.
Maintenance Step-by-step procedures that describe how to perform
maintenanceoftherobot.Basedonamaintenanceschedule 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.
Calibration information Procedures that do not require specific calibration equipment.
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
documents, safety standards etc.
Spare part / part list Complete spare part list and complete list of robot components,
shown in exploded views.
Exploded views Detailed illustrations of the robot with reference numbers to the
part list.
Circuit diagram Reference to the circuit diagram for the robot..
Reference Document ID
Product specification - IRB 120 3HAC035960-001
Product manual - IRC5 3HAC021313-001
Product manual - IRC5 Compact 3HAC035738-001
Product manual - Panel Mounted Controller 3HAC027707-001
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Emergency safety information 3HAC027098-001
Same document
number regardless of
language.
General safety information 3HAC031045-001
Continued
Continues on next page

Overview of this manual
93HAC035728-001 Revision: B
© Copyright 2009-2010 ABB. All rights reserved.
Revisions
Revision Description
-First edition
AThis revision includes the following additions and/or changes:
• Section "Product documentation, M2004" added.
• Section "How to read the product manual" added.
•Safety chapter- Updatedsafetysignal graphicsfor levelsDanger! and
Warning! See section Safety signals in the manual on page 33.
•Safety chapter - New safety labels on the manipulators, see Safety
symbols on the manipulator labels on page 35.
•Safety chapter- Revised terminology: robot replaced with manipula-
tor.
•Safety chapter - Information not applicable to IRB 120 in WARNING
- Safety risks during work with gearbox lubricants (oil or grease) on
page 43 removed.
•Installation chapter- Illustration updated in Risk of tipping/Stability on
page 51.
•Installation chapter- Attachment screws added in Lifting the robot
with roundslings on page 52.
•Installation chapter- Value in illustration updated in Orienting and
securing the robot on page 58.
•Installation chapter - Section Suspended mounting on page 64 new.
•Installation chapter -SectionRobot cablingand connection pointson
page 70 updated.
•Installation chapter - Section Customer connections on robot on
page 71 art. no. on connection at upper arm updated.
•Maintenance chapter - Value for timing belt tension axis 5 updated.
•Repair chapter - New chapter.
•Calibration chapter - Section Calibrating axes 1 - 6 on page 174
updated.
•Calibration chapter - Section Synchronization marks axes 1-6 on
page 180 updated.
•Reference information chapter - New chapter.
•Spare parts chapter - Article numbers and illustrations updated.
Continued
Continues on next page

Overview of this manual
3HAC035728-001 Revision: B10
© Copyright 2009-2010 ABB. All rights reserved.
BThis revision includes the following additions and/or changes:
•Installation chapter - Lifting capacity of roundslings updated. See:
Lifting the robot with roundslings on page 52.
•Installation chapter - New illustration showing IRB 120 added. See:
Suspended mounting on page 64.
•Repair chapter - Illustrations xx0900001009 and xx0900000782
updated. See: Removing the cable harness on page 96 and Refitting
the cable harness on page 107.
•Repair chapter - Illustration xx0900000924 updated. See: Replacing
the upper arm on page 122.
•Repair chapter - Motor axis 4 now delivered as part of the upper arm.
The procedures Removal and Refitting are updated accordingly. See:
Replacing the upper arm on page 122.
•Repair chapter - Motor axis 4 now delivered as part of the upper arm.
The section is updated accordingly. See: Replacing motor axis 4, with
gearbox on page 159.
•Repair chapter - Illustration xx0900001009 updated. See: Replacing
motor axis 5 on page 160.
•Calibration chapter updated. See sections: Calibrating axes 1 - 6 on
page 174 and Synchronization marks axes 1-6 on page 180.
•Reference information chapter - "Other standards" added. See:
Applicable safety standards on page 186.
•Reference information chapter - Standard toolkit updated. See:
Standard toolkit on page 191.
•Spare parts chapter - Motor axis 4 (art. no. 3HAC037282-001)
removed.Nowpartoftheupper arm.See: Spareparts-Upper arm unit
on page 201.
•Circuit diagram - Updated after circuit diagrams now are delivered as
separate files. See: About circuit diagrams on page 207.
Revision Description
Continued

Product documentation, M2004
113HAC035728-001 Revision: B
© Copyright 2009-2010 ABB. All rights reserved.
Product documentation, M2004
Categories for manipulator documentation
The manipulator documentation 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
M2004 manipulator systems.
Product manuals All hardware, manipulators and controllers will be delivered with a Product manual that
contains:
•Safety information.
•Installation and commissioning (descriptions of mechanical installation, electrical
connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals).
•Repair (descriptions of all recommended repair procedures including spare parts).
•Additional procedures, if any (calibration, decommissioning).
•Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards).
•Parts list.
•Foldouts or exploded views.
•Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe the manipulator software in general and contain
relevant reference information.
•RAPID Overview: An overview of the RAPID programming language.
•RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions, and data types.
•RAPID Kernel: A formal description of the RAPID programming language.
•System parameters: Description of system parameters and configuration workflows.
Application manualsSpecific 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, CD with PC software).
•How to use the application.
•Examples of how to use the application.
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Product documentation, M2004
3HAC035728-001 Revision: B12
© Copyright 2009-2010 ABB. All rights reserved.
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:
•Emergency safety information
•General safety information
•Getting started, IRC5 and RobotStudio
•IRC5 with FlexPendant
•RobotStudio
•Introduction to RAPID
•Trouble shooting, for the controller and manipulator.
Continued

How to read the product manual
133HAC035728-001 Revision: B
© Copyright 2009-2010 ABB. All rights reserved.
How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, etc. The references are read as
described below.
References to figures The procedures often include references to components or attachment points located on the
manipulator/controller. The components or attachment points are marked with italic text in
the procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a procedure.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.) required for the
different actions in the procedure. The equipment is marked with italic text in the procedures
and completed with a reference to the section where the equipment is listed with further
information, that is article number and dimensions.
The designation in the procedure for the component or attachment point corresponds to the
designation in the referenced list.
The table below shows an example of a reference to a list of required equipment from a step
in a procedure.
Safety information The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in the chapter Safety on page 15.
Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.
Action Note/Illustration
3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.

How to read the product manual
3HAC035728-001 Revision: B14
© Copyright 2009-2010 ABB. All rights reserved.

1 Safety
1.1. Introduction to safety information
153HAC035728-001 Revision: B
© Copyright 2009-2010 ABB. All rights reserved.
1 Safety
1.1. Introduction to safety information
Overview The safety information in this manual is divided in two categories:
•General safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in General safety
information on page 16.
•Specific safety information, pointed out in the procedures. How to avoid and eliminate
the danger is either described directly in the procedure, or in specific instructions in
the section Safety related instructions on page 33.

1 Safety
1.2.1. Safety in the manipulator system
3HAC035728-001 Revision: B16
© Copyright 2009-2010 ABB. All rights reserved.
1.2 General safety information
1.2.1. Safety in the manipulator system
Validity and responsibility
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 total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the
manipulator is installed.
The users of ABB industrial manipulators are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the safety devices
necessary to protect people working with the manipulator system are designed and installed
correctly. Personnel working with manipulators must be familiar with the operation and
handling of the industrial manipulator as described in the applicable documents, for example:
•Operating manual - IRC5 with FlexPendant
•Product manual
Connection of external safety devices
Apart from the built-in safety functions, the manipulator is also supplied with an interface for
the connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the manipulator.
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty
by ABB that the industrial manipulator will not cause injury or damage even if all safety
instructions are complied with.
Related information
Type of information Detailed in document Section
Installation of safety
devices Product manual for the manipulator Installation and commissioning
Changing operating
modes Operating manual - IRC5 with FlexPendant Operating modes
Restricting the working
space Product manual for the manipulator Installation and commissioning

1 Safety
1.2.2.1. Safety risks during installation and service work on manipulators
173HAC035728-001 Revision: B
© Copyright 2009-2010 ABB. All rights reserved.
1.2.2. Safety risks
1.2.2.1. Safety risks during installation and service work on manipulators
Overview This section includes information on general safety risks to be considered when performing
installation and service work on the manipulator.
General risks during installation and service
•The instructions in the Product manual in the chapter Installation and commissioning
must always be followed.
•Emergency stop buttons must be positioned in easily accessible places so that the
manipulator can be stopped quickly.
•Those in charge of operations must make sure that safety instructions are available for
the installation in question.
•Those who install the manipulator must have the appropriate training for the
equipment in question and in any safety matters associated with it.
Nation/region specific regulations
To prevent injuries and damage during the installation of the manipulator, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
Non-voltage related risks
•Safety zones, which must be crossed before admittance, must be set up in front of the
manipulator'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 manipulator's
working space.
•The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving manipulator parts, there is a risk of being crushed
by the parallel arm (if there is one).
•Energy stored in the manipulator for the purpose of counterbalancing certain axes may
be released if the manipulator, or parts thereof, are dismantled.
•When dismantling/assembling mechanical units, watch out for falling objects.
•Be aware of stored heat energy in the controller.
•Never use the manipulator as a ladder, that is, do not climb on the manipulator motors
or other parts during service work. There is a risk of the manipulator being damaged.
To be observed by the supplier of the complete system
•The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
•The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.
Continues on next page

1 Safety
1.2.2.1. Safety risks during installation and service work on manipulators
3HAC035728-001 Revision: B18
© Copyright 2009-2010 ABB. All rights reserved.
Complete manipulator
Cabling
Gearboxes and motors
Safety risk Description
Hot components!
CAUTION!
Motors and gears are HOT after running the manipulator!
Touching motors and gears may result in burns!
Withahigherenvironmenttemperature,moresurfaceson
the manipulator will get HOT and may also result in burns.
Removed parts may result in
collapse of manipulator!
WARNING!
Take any necessary measures to ensure that the
manipulator does not collapse as parts are removed, e.g.
secure the lower arm with fixtures if removing motor, axis
2.
Safety risk Description
Cable packs are sensitive to
mechanical damage!
CAUTION!
The cable packs are sensitive to mechanical damage!
They must be handled with care, especially the
connectors, in order to avoid damaging them!
Safety risk Description
Gears may be damaged if
excessive force is used!
CAUTION!
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!
Continued