ABB IRB 1200-5/0.9 User manual

Product manual, spare parts
IRB 1200

Trace back information:
Workspace R17-1 version a7
Checked in 2017-03-22
Skribenta version 5.1.011

Product manual, spare parts
IRB 1200-5/0.9
IRB 1200-5/0.9 type A
IRB 1200-5/0.9 type B
IRB 1200-7/0.7
IRB 1200-7/0.7 type A
IRB 1200-7/0.7 type B
IRC5
Document ID: 3HAC046984-001
Revision: D
© Copyright 2014 - 2017 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.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2014 - 2017 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
7Overview of this manual ...................................................................................................................
9Product documentation, IRC5 ..........................................................................................................
111 Spare parts and exploded views
111.1 Spare parts - electrical parts ................................................................................ 191.2 Spare parts - base ............................................................................................. 221.3 Spare parts - swing ............................................................................................ 281.4 Spare parts - housing ......................................................................................... 311.5 Spare parts - housing extender unit ...................................................................... 331.6 Spare parts - lower arm ...................................................................................... 361.7 Spare parts - tubular .......................................................................................... 381.8 Spare parts - tilt unit parts ................................................................................... 401.9 Spare parts - motors .......................................................................................... 401.9.1 Spare parts - axis-1 motor ......................................................................... 411.9.2 Spare parts - axis-2 motor ......................................................................... 421.9.3 Spare parts - axis-3 motor ......................................................................... 431.9.4 Spare parts - axis-4 motor ......................................................................... 451.9.5 Spare parts - axis-5 motor ......................................................................... 461.9.6 Spare parts - axis-6 motor ......................................................................... 471.10 Spare parts - gears ............................................................................................ 471.10.1 Spare parts - axis-1 gear unit ..................................................................... 481.10.2 Spare parts - axis-2 drive unit .................................................................... 501.10.3 Spare parts - axis-3 drive unit .................................................................... 521.10.4 Spare parts - axis-4 gearbox ...................................................................... 531.10.5 Spare parts - axis-5 and axis-6 drive unit ..................................................... 551.11 Spare parts - information labels ........................................................................... 591.12 Spare parts - Axis Calibration items ...................................................................... 621.13 Spare parts - options .........................................................................................
632 Robot description
632.1 Type A of IRB 1200 ........................................................................................... 642.2 Type B of IRB 1200 ........................................................................................... 652.3 Description of spare part versions ........................................................................ 652.3.1 Spare part versions for the base on IP40/IP67 robots ..................................... 672.3.2 Spare part versions for the swing on IP40/IP67 robots .................................... 692.3.3 Spare part versions for the axis-1 sealing ring on IP40/IP67 robots ................... 702.3.4 Spare part versions for the housing on Type A robots .................................... 712.3.5 Spare part versions for the tubular on Type A robots ..................................... 722.3.6 Spare part versions for the tubular cover on Clean Room robots ......................
73Index
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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 1200 and all its variants.
Usage
This manual shall be used as a complement to the product manual for IRB 1200
during:
• maintenance work
• repair work.
Who should read this manual?
This manual is intended for:
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
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 parts and exploded view
References
Document IDReference
3HAC046983-001Product manual - IRB 1200
3HAC046307-003Circuit diagram - IRB 1200
Revisions
DescriptionRevision
First edition-
The following updates are made in this revision:
• The spare part numbers for the battery pack and the axis-4 FPC unit
are changed.
A
The following updates are made in this revision:
• The spare part numbers for the base, the swing and some of the
sealings between the base and swing are updated.
• Spare parts with food grade lubrication added.
• Spare part numbers for several gaskets (IP67) updated.
B
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Overview of this manual

DescriptionRevision
Published in release R16.2. The following updates are done in this revision:
• Spare part illustration updated, in Spare parts - base on page 19,
Spare parts - swing on page 22, and Spare parts - information labels
on page 55.
• Spare parts that are affected by Axis Calibration and Foundry Plus
are updated.
• Spare part items that belong to the standard calibration method (Axis
Calibration) added. See Spare parts - Axis Calibration items on
page 59.
• Protection plug for the calibration hole in the swing added, see Spare
parts - swing on page 22.
C
Published in release R17.1. The following updates are done in this revision:
• 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 65.
• Spare part items that belong to SafeMove 2 added.
• Spare part lists restructured based on options.
• Plug on base added to options IP67 and Foundry Plus.
D
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Overview of this manual
Continued

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.
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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 - IRC5 Integrator's guide
•Operating manual - IRC5 with FlexPendant
•Operating manual - RobotStudio
•Operating manual - Trouble shooting IRC5
10 Product manual, spare parts - IRB 1200
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Product documentation, IRC5
Continued

1 Spare parts and exploded views
1.1 Spare parts - electrical parts
Manipulator cable harness
Spare part list - IRB 1200 (no type specified) and IRB 1200 Type A
Food Grade lubrication Clean Room Foundry Plus IP67 Standard (IP40)
DescriptionSpare part number
XXXManipulator cable harness with Ethernet (rear
interface)
3HAC059673-001A
XXXManipulator cable harness without Ethernet
(rear interface)
3HAC059674-001
XXManipulator cable harness with Ethernet (rear
interface), Clean Room
3HAC056219-001
Manipulator cable harness with Ethernet (rear
interface), food grade lubrication
XXManipulator cable harness without Ethernet
(rear interface), Clean Room
3HAC056220-001
Manipulator cable harness without Ethernet
(rear interface), food grade lubrication
XXXXXManipulator cable harness with Ethernet
(bottom interface)
3HAC051415-001B
XXXXXManipulator cable harness without Ethernet
(bottom interface)
3HAC051416-001
Spare part list - IRB 1200 Type B
Food Grade lubrication Clean Room Foundry Plus IP67 Standard (IP40)
DescriptionSpare part number
XXXManipulator cable harness with Ethernet (rear
interface), SafeMove 2-supported
3HAC061282-001A
XXXManipulator cable harness without Ethernet
(rear interface), SafeMove 2-supported
3HAC061283-001
XXManipulator cable harness with Ethernet (rear
interface), Clean Room and SafeMove 2-sup-
ported
3HAC061286-001
Manipulator cable harness with Ethernet (rear
interface), food grade lubrication and Safe-
Move 2-supported
XXManipulator cable harness without Ethernet
(rear interface), Clean Room and SafeMove
2-supported
3HAC061287-001
Manipulator cable harness without Ethernet
(rear interface), food grade lubrication and
SafeMove 2-supported
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1 Spare parts and exploded views
1.1 Spare parts - electrical parts

Food Grade lubrication Clean Room Foundry Plus IP67 Standard (IP40)
DescriptionSpare part number
XXXXXManipulator cable harness with Ethernet
(bottom interface), SafeMove 2-supported
3HAC061284-001B
XXXXXManipulator cable harness without Ethernet
(bottom interface), SafeMove 2-supported
3HAC061285-001
Spare part illustration
B: Manipulator harness with bottom inter-
face (option)
A: Manipulator harness with rear interface
(standard)
xx1400000410
xx1300002414
Manipulator cable harness parts
Spare part list
Food Grade lubrication Clean Room Foundry Plus IP67 Standard (IP40)
NoteDescriptionSpare part number
XXXXXIncludes tubular flange, air
connectors and seal bolts.
Air connector set with Ether-
net hole in flange
3HAC049664-001A
Replace if damaged.
XXXXXIncludes tubular flange, air
connectors and seal bolts.
Air connector set without Eth-
ernet hole in flange
3HAC049665-001
Replace if damaged.
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1 Spare parts and exploded views
1.1 Spare parts - electrical parts
Continued

Food Grade lubrication Clean Room Foundry Plus IP67 Standard (IP40)
NoteDescriptionSpare part number
XXGasket3HAC058567-001B
XXXXOne-way valve3HAC044906-001C
XXXXXBase bottom cover (standard
configuration)
3HAC049667-001D
XXXXGasket for rear base cover3HAC058566-001E
XXXXXFPC unit, axis 43HAC055517-001F
XXXXXFPC unit, axis 53HAC045743-001G
XXXBase rear cover, without con-
nector interface
3HAC059675-001H
XXBase rear cover, without con-
nector interface, Clean Room
3HAC056147-001
Base rear cover, without con-
nector interface, food grade
lubrication
XXXXXDust cap3HEA800897-002J
XXXXXM12 protector3HAC047543-001K
XProtection bracket for CP/CS
connectors
3HAC058350-001L
XXXXXIncludes brackets, sheets,
distance screws, plastics,
cable clamp, seal bolts and air
protection in tubular.
Cable harness material set3HAC049663-001-
XXXXXCable harness CP/CS3HAC032296-001-
XXXXXR1.CP/CS connector set3HAC037038-001-
XXXXXR3.CP/CS connector set3HAC037070-001-
XXXXXO-ring3HAB3772-141-
XXXXXM12 plug (CP/CS)3HAC047542-001-
XXXXXRJ 45 plug (CP/CS)3HAC047538-001-
XXXXXEthernet cable harness for
upper arm
3HAC047540-001-
XXXXXO-ring3HAB3772-19-
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1 Spare parts and exploded views
1.1 Spare parts - electrical parts
Continued

Spare part illustration
xx1400000653
xx1400000675
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1 Spare parts and exploded views
1.1 Spare parts - electrical parts
Continued

xx1400000824
xx1400000830
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1 Spare parts and exploded views
1.1 Spare parts - electrical parts
Continued

xx1400000832
xx1600001040
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1 Spare parts and exploded views
1.1 Spare parts - electrical parts
Continued

EIB unit parts - IRB 1200 (no type specified) and IRB 1200 Type A
Spare part list
Food Grade lubrication Clean Room Foundry Plus IP67 Standard (IP40)
NoteDescriptionSpare part number
XXXXXEIB unit3HAC045759-001A
XXXXXBattery includes protection
circuits. Only replace with a
specified spare part or an
ABB-approved equivalent.
Battery pack3HAC051036-001B
Spare part illustration
xx1400000676
SMB unit parts - IRB 1200 Type B
Spare part list
Food Grade lubrication Clean Room Foundry Plus IP67 Standard (IP40)
NoteDescriptionSpare part number
XXXXXSMB unit3HAC059122-001A
XXXXXUsed for IRB 1200 Type B.
See Type B of IRB 1200 on
page 64.
Battery pack, SafeMove
2-supported
3HAC044075-001B
Battery includes protection
circuits. Only replace with a
specified spare part or an
ABB-approved equivalent.
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1 Spare parts and exploded views
1.1 Spare parts - electrical parts
Continued

Spare part illustration
xx1600002099
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1 Spare parts and exploded views
1.1 Spare parts - electrical parts
Continued

1.2 Spare parts - base
Base
Spare part list - IRB 1200 (no type specified) and IRB 1200 Type A
The base spare part for IRB 1200 (no type specified) and IRB 1200 Type A includes
base machining, axis-1 gear unit and axis-1 AC motor with encoder interface.
Food Grade lubrication Clean Room Foundry Plus IP67 Standard (IP40)
DescriptionSpare part number
XXX
Basei
3HAC059553-001A
XBase, Clean Room3HAC059699-001
XBase, food grade lubrication3HAC057906-001
iIncompatible with swing 3HAC049632-001. See Spare part versions for the base on IP40/IP67
robots on page 65.
Spare part list - IRB 1200 Type B
The base spare part for IRB 1200 Type B includes base machining, axis-1 gear
unit and axis-1 AC motor with resolver interface.
Food Grade lubrication Clean Room Foundry Plus IP67 Standard (IP40)
DescriptionSpare part number
XXXBase, SafeMove 2-supported3HAC061270-001A
XBase, Clean Room and SafeMove 2-sup-
ported
3HAC061271-001
XBase, food grade lubrication and Safe-
Move 2-supported
3HAC061272-001
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1 Spare parts and exploded views
1.2 Spare parts - base

Spare part illustration
xx1400000654
Base parts
Spare part list
Food Grade lubrication Clean Room Foundry Plus IP67 Standard (IP40)
NoteDescriptionSpare part number
XXXXRadial sealing with dust lip3HAB3701-47A
XUsed with protection class
IP67.
M2 variseal sealing3HAC044641-002-
Used only on base
3HAC049628-001. See Spare
part versions for the base on
IP40/IP67 robots on page 65.
Replace if damaged.
XXXXXCable protection sleeve inside
base
3HAC044690-001C
XXXXO-ring3HAB3772-86D
XXXXXBase bottom cover (standard
configuration)
3HAC049667-001E
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1 Spare parts and exploded views
1.2 Spare parts - base
Continued