ABB IRB 1300 Product Manual 770 Pages
ABB IRB 1300 Product Manual
ABB IRB 1300 is a versatile industrial robot designed for a variety of applications, including material handling, assembly, and machine tending. It features a compact design, high payload capacity, and a wide range of motion, making it suitable for tasks that require precision and speed. The IRB 1300 is available in different configurations to meet specific needs, including standard, IP67, Foundry Plus, and Clean Room versions.
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ROBOTICS Product manual IRB 1300 Trace back information: Workspace 22A version a22 Checked in 2022-03-21 Skribenta version 5.5.019 Product manual IRB 1300-11/0.9 IRB 1300-10/1.15 IRB 1300-7/1.4 IRB 1300-12/1.4 OmniCore Document ID: 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. Specifications subject to change without notice. The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage 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 2020-2022 ABB. All rights reserved. Specifications subject to change without notice. Table of contents Table of contents Overview of this manual ................................................................................................................... 9 Product documentation .................................................................................................................... 12 How to read the product manual ...................................................................................................... 14 1 Safety 15 1.1 15 15 16 17 17 19 25 26 28 29 29 32 33 34 35 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2 3 Safety information ............................................................................................. 1.1.1 Limitation of liability ................................................................................. 1.1.2 Requirements on personnel ...................................................................... Safety signals and symbols ................................................................................. 1.2.1 Safety signals in the manual ...................................................................... 1.2.2 Safety symbols on manipulator labels ......................................................... Robot stopping functions .................................................................................... Safety during installation and commissioning ......................................................... Safety during operation ...................................................................................... Safety during maintenance and repair ................................................................... 1.6.1 Safety during maintenance and repair ......................................................... 1.6.2 Emergency release of the robot axes .......................................................... 1.6.3 Brake testing .......................................................................................... Safety during troubleshooting .............................................................................. Safety during decommissioning ........................................................................... Technical data 37 2.1 2.2 2.3 2.4 37 41 44 50 Technical data .................................................................................................. Dimensions ...................................................................................................... Working range ................................................................................................. The unit is sensitive to ESD ................................................................................. Installation and commissioning 51 3.1 3.2 51 52 52 53 55 56 58 58 58 64 65 67 71 74 75 83 85 85 86 89 89 90 90 94 97 99 3.3 3.4 3.5 3.6 3.7 3.8 Introduction to installation and commissioning ....................................................... Unpacking ....................................................................................................... 3.2.1 Pre-installation procedure ......................................................................... 3.2.2 Risk of tipping/stability ............................................................................. 3.2.3 Extra O-rings .......................................................................................... 3.2.4 Transportation bracket ............................................................................. On-site installation ............................................................................................ 3.3.1 Lifting the robot ...................................................................................... 3.3.1.1 Lifting the robot with roundslings .................................................... 3.3.1.2 Lifting and rotating a suspended mounted manipulator ....................... 3.3.2 Manually releasing the brakes ................................................................... 3.3.3 Orienting and securing the robot ............................................................... 3.3.4 Setting the system parameters for an inverted or a tilted robot ......................... 3.3.5 Loads fitted to the robot, stopping time and braking distances ......................... 3.3.6 Fitting equipment on the robot (robot dimensions) ......................................... 3.3.7 Installation of signal lamp (option) .............................................................. Restricting the working range .............................................................................. 3.4.1 Adjusting the working range ...................................................................... 3.4.2 Mechanically restricting the working range ................................................... Making robot ready for operation .......................................................................... 3.5.1 Additional installation procedure, Clean Room .............................................. Electrical connections ........................................................................................ 3.6.1 Robot cabling and connection points .......................................................... 3.6.2 Customer connections ............................................................................. Start of robot in cold environments ...................................................................... Test run after installation, maintenance, or repair .................................................... Product manual - IRB 1300 5 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. Table of contents 4 Maintenance 101 4.1 4.2 101 102 102 103 105 106 106 108 108 110 111 115 119 119 122 122 129 129 130 135 4.3 4.4 4.5 4.6 4.7 5 Introduction ...................................................................................................... Maintenance schedule and expected component life ............................................... 4.2.1 Specification of maintenance intervals ........................................................ 4.2.2 Maintenance schedule ............................................................................. 4.2.3 Expected component life ......................................................................... Cleaning activities ............................................................................................. 4.3.1 Cleaning the IRB 1300 .............................................................................. Inspection activities ........................................................................................... 4.4.1 Inspecting the information labels ................................................................ 4.4.2 Inspecting the robot cabling ..................................................................... 4.4.3 Inspecting mechanical stops ..................................................................... 4.4.4 Inspecting timing belts ............................................................................ Lubrication activities .......................................................................................... 4.5.1 Lubricating the cable package ................................................................... Replacement activities ....................................................................................... 4.6.1 Replacing the battery pack ........................................................................ Changing activities ............................................................................................ 4.7.1 Type of lubrication in gearboxes ................................................................ 4.7.2 Changing oil, axis-1 gearbox ..................................................................... 4.7.3 Changing oil, axis-2 gearbox ..................................................................... Repair 141 5.1 5.2 141 142 142 145 147 148 148 193 202 208 208 237 290 292 294 294 359 412 486 489 491 491 507 523 534 545 562 578 578 585 638 676 5.3 5.4 5.5 5.6 5.7 Introduction ...................................................................................................... General procedures ........................................................................................... 5.2.1 Mounting instructions for sealings .............................................................. 5.2.2 Cut the paint or surface on the robot before replacing parts ............................ 5.2.3 The brake release buttons may be jammed after service work ......................... Cable harness .................................................................................................. 5.3.1 Replacing the cable package ..................................................................... 5.3.2 Replacing the SMB unit ........................................................................... 5.3.3 Replacing the brake release unit ................................................................ Swing and base ................................................................................................ 5.4.1 Replacing the base .................................................................................. 5.4.2 Replacing the swing ................................................................................ 5.4.3 Replacing the axis-1 mechanical stops ........................................................ 5.4.4 Replacing the axis-2 mechanical stops ........................................................ Upper and lower arms ........................................................................................ 5.5.1 Replacing the lower arm ........................................................................... 5.5.2 Replacing the housing and extender unit ..................................................... 5.5.3 Replacing the tubular and tilt unit ............................................................... 5.5.4 Replacing the axis-3 mechanical stops ........................................................ 5.5.5 Replacing the axis-4 mechanical stops ........................................................ Motors ............................................................................................................ 5.6.1 Replacing the axis-1 motor ........................................................................ 5.6.2 Replacing the axis-2 motor ........................................................................ 5.6.3 Replacing the axis-3 motor ........................................................................ 5.6.4 Replacing the axis-4 motor ........................................................................ 5.6.5 Replacing the axis-5 motor ........................................................................ 5.6.6 Replacing the axis-6 motor ........................................................................ Gearboxes ....................................................................................................... 5.7.1 Replacing the axis-1 gearbox .................................................................... 5.7.2 Replacing the axis-2 gearbox .................................................................... 5.7.3 Replacing the axis-3 gearbox .................................................................... 5.7.4 Replacing the axis-4 gearbox .................................................................... 6 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. Table of contents 6 Calibration 713 6.1 713 713 714 716 717 717 718 719 719 721 721 724 727 730 735 737 738 6.2 6.3 6.4 6.5 6.6 7 8 Troubleshooting 739 7.1 7.2 7.3 7.4 7.5 739 741 742 744 745 Introduction to troubleshooting ............................................................................ Oil and grease stains on motors and gearboxes ...................................................... Mechanical noise or dissonance .......................................................................... Manipulator collapses on power down ................................................................... Motor temperature too high ................................................................................. Decommissioning 8.1 8.2 8.3 9 Introduction to calibration ................................................................................... 6.1.1 Introduction and calibration terminology ...................................................... 6.1.2 Calibration methods ................................................................................. 6.1.3 When to calibrate ................................................................................... Synchronization marks and axis movement directions ............................................. 6.2.1 Synchronization marks and synchronization position for axes ......................... 6.2.2 Calibration movement directions for all axes ................................................ Updating revolution counters ............................................................................... 6.3.1 Updating revolution counters on OmniCore robots ........................................ Calibrating with Axis Calibration method ............................................................... 6.4.1 Description of Axis Calibration .................................................................. 6.4.2 Calibration tools for Axis Calibration ........................................................... 6.4.3 Installation locations for the calibration tools ............................................... 6.4.4 Axis Calibration - Running the calibration procedure ...................................... 6.4.5 Reference calibration ............................................................................... Verifying the calibration ...................................................................................... Checking the synchronization position .................................................................. 747 Introduction ...................................................................................................... 747 Environmental information .................................................................................. 748 Scrapping of robot ............................................................................................. 750 Reference information 751 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 751 752 754 755 758 759 760 761 Introduction ...................................................................................................... Applicable standards ......................................................................................... Unit conversion ................................................................................................. Screw joints .................................................................................................... Weight specifications ......................................................................................... Standard toolkit ................................................................................................ Special tools .................................................................................................... Lifting accessories and lifting instructions .............................................................. 10 Spare parts 763 10.1 Spare part lists and illustrations ........................................................................... 763 Index 765 Product manual - IRB 1300 7 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. This page is intentionally left blank Overview of this manual Overview of this manual About this manual This manual contains instructions for: • mechanical and electrical installation of the IRB 1300 • maintenance of the IRB 1300 • mechanical and electrical repair of the IRB 1300 The robot described in this manual has the following protection types: • Standard • IP67 • Foundry Plus • Clean Room Usage This manual should be used during: • installation and commissioning, from lifting the product to its work site and securing it to the foundation, to making it ready for operation • maintenance work • repair work • decommissioning work Note It is the responsibility of the integrator to conduct a risk assessment of the final application. It is the responsibility of the integrator to provide safety and user guides for the robot system. 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. • be trained to respond to emergencies or abnormal situations. Product manual scope The manual covers all variants and designs of the IRB 1300. Some variants and designs may have been removed from the business offer and are no longer available for purchase. Continues on next page Product manual - IRB 1300 9 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. Overview of this manual Continued References Documentation referred to in the manual, is listed in the table below. Document name Document ID Product manual, spare parts - IRB 1300 3HAC070392-001 Product specification - IRB 1300 3HAC070393-001 Circuit diagram - IRB 1300 3HAC068887-003 Safety manual for robot - Manipulator and IRC5 or OmniCore con- 3HAC031045-001 troller i Product manual - OmniCore C30 3HAC060860-001 Product manual - OmniCore C90XT 3HAC073706-001 Product manual - OmniCore E10 3HAC079399-001 Operating manual - OmniCore 3HAC065036-001 Application manual - Controller software OmniCore 3HAC066554-001 Application manual - CalibWare Field 3HAC030421-001 Technical reference manual - Event logs for RobotWare 7 3HAC066553-001 Technical reference manual - Lubrication in gearboxes 3HAC042927-001 Technical reference manual - System parameters 3HAC065041-001 i This manual contains all safety instructions from the product manuals for the manipulators and the controllers. Revisions Revision Description A First edition. B Published in release 20D. The following updates are made in this revision: • Installation of signal lamp is added. • Information about mechanical restriction of axis-5 working range is updated and a figure showing related location is added. • A new O-ring on swing (3HAC061327-036) is added. • Updated cleaning method. • Added maximum arm load information and updated the load area figure. C Published in release 21A. The following updates are made in this revision: • Protection class IP67 (option 3350-670), protection type Clean Room (option 3351-4) and protection type Foundry Plus (option 3352-10) are added. • Figure of tool flange standard is updated. • Specification of connectors R1.C3 and R2.C3 is updated. • Connector types for CP/CS and Ethernet floor cable wiring are added. • A note about adding flange sealing Loctite 577 to the quick coupling on the base is added. • Minor changes. Continues on next page 10 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. Overview of this manual Continued Revision Description D Published in release 21B. The following updates are done in this revision: • Text regarding fastener quality is updated, see Fastener quality on page 82. • Text regarding diameter of air hoses is updated, see Customer connections on page 94. • Added maintenance activities of running the Brake Check and Cyclic Brake Check routines. See Maintenance schedule on page 103. • Removed maintenance activity of inspecting oil seepage and updated troubleshooting description about oil and grease stains on motors and gearboxes. • Updated tool flange dimension images. • Added a note to remind users that mechanical stop locations cannot be adjusted. See Adjusting the working range on page 85. E Published in release 21C. The following updates are done in this revision: • Updated the tool flange standard figure for IP40, IP67 and Clean Room robots. • Updated the information of foundation guide pins. • Supported controller OmniCore E10 is added. • Corrected the description of connection point on cabinet. • Updated the naming of timing belt tension adjustment tools, from acoustic tensiometer and tensiometer to sonic tension meter and dynamometer, respectively. F Published in release 21D. The following updates are done in this revision: • Updated the standard toolkit table. G Published in release 22A. The following updates are done in this revision: • Added variant IRB 1300-12/1.4. • Updated information of screws for fixing the housing to extender unit or tubular. • Updated the complete robot weight. • Added a note for inspecting the oil level of axis-2 gearbox. • Added information about length of thread engagement for attachment screws. • Added cautions in procedures of removing timing belts, motors and gearboxes. • Updated tightening torques for some screws. • Updated dimension figures to include dimension for bottom connector interface option. • Added troubleshooting for high motor temperature, see Motor temperature too high on page 745. • Updated information about Gleitmo treated screws, see Screw joints on page 755. Product manual - IRB 1300 11 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. Product documentation 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. Tip All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manuals Manipulators, controllers, DressPack/SpotPack, and most other hardware is delivered with a Product manual that generally contains: • Safety information. • Installation and commissioning (descriptions of mechanical installation or electrical connections). • Maintenance (descriptions of all required preventive maintenance procedures including intervals and expected life time of parts). • Repair (descriptions of all recommended repair procedures including spare parts). • Calibration. • Decommissioning. • Reference information (safety standards, unit conversions, screw joints, lists of tools). • Spare parts list with corresponding figures (or references to separate spare parts lists). • References to circuit diagrams. Technical reference manuals The technical reference manuals describe reference information for robotics products, for example lubrication, the RAPID language, and system parameters. Application manuals Specific applications (for example software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: • The purpose of the application (what it does and when it is useful). • What is included (for example cables, I/O boards, RAPID instructions, system parameters, software). • How to install included or required hardware. • How to use the application. • Examples of how to use the application. Continues on next page 12 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. Product documentation Continued Operating manuals The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 1300 13 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. How to read the product manual How to read the product manual Reading the procedures The procedures contain all information required for the installation or service activity and can be printed out separately when needed for a certain service procedure. Safety information The manual includes a separate safety chapter that must be read through before proceeding with any service or installation procedures. All procedures also include specific safety information when dangerous steps are to be performed. Read more in the chapter Safety on page 15. 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. 14 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.1.1 Limitation of liability 1 Safety 1.1 Safety information 1.1.1 Limitation of liability 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 robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system. In particular, liability cannot be accepted if injury or 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 of the robot. • Repairs on the robot and its spare parts carried out by in-experienced or non-qualified personnel. • Foreign objects. • Force majeure. Spare parts and equipment ABB supplies original spare parts and equipment which have been tested and approved. The installation and/or use of non-original spare parts and equipment can negatively affect the safety, function, performance, and structural properties of the robot. ABB is not liable for damages caused by the use of non-original spare parts and equipment. Product manual - IRB 1300 15 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.1.2 Requirements on personnel 1.1.2 Requirements on personnel General Only personnel with appropriate training are allowed to install, maintain, service, repair, and use the robot. This includes electrical, mechanical, hydraulics, pneumatics, and other hazards identified in the risk assessment. Persons who are under the influence of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, service, repair, or use the robot. The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. 16 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.2.1 Safety signals in the manual 1.2 Safety signals and symbols 1.2.1 Safety signals in the manual Introduction to safety signals This section specifies all safety signals used in the user manuals. Each signal consists of: • A caption specifying the hazard level (DANGER, WARNING, or CAUTION) and the type of hazard. • Instruction about how to reduce the hazard to an acceptable level. • A brief description of remaining hazards, if not adequately reduced. Hazard levels The table below defines the captions specifying the hazard levels used throughout this manual. Symbol Designation Significance DANGER Signal word used to indicate an imminently hazardous situation which, if not avoided, will result in serious injury. WARNING Signal word used to indicate a potentially hazardous situation which, if not avoided, could result in serious injury. ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous situation related to electrical hazards which, if not avoided, could result in serious injury. CAUTION Signal word used to indicate a potentially hazardous situation which, if not avoided, could result in slight injury. ELECTROSTATIC Signal word used to indicate a potentially hazardous DISCHARGE (ESD) situation which, if not avoided, could result in severe damage to the product. NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 1300 17 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.2.1 Safety signals in the manual Continued Symbol Designation Significance TIP Signal word used to indicate where to find additional information or how to do an operation in an easier way. 18 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.2.2 Safety symbols on manipulator labels 1.2.2 Safety symbols on manipulator labels Introduction to symbols This section describes safety symbols used on labels (stickers) on the manipulator. 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 symbols on the labels on the product must be observed. Additional symbols added by the integrator must also be observed. Types of symbols Both the manipulator and the controller are marked with symbols, containing important information about the product. This is important 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 19. The information labels can contain information in text. Symbols on safety labels Symbol xx0900000812 xx0900000811 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 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, impact, 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 Continues on next page Product manual - IRB 1300 19 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.2.2 Safety symbols on manipulator labels Continued Symbol Description See user documentation Read user documentation for details. Which manual to read is defined by the symbol: • No text: Product manual. xx0900000813 Before disassembly, see product manual xx0900000816 Do not disassemble Disassembling this part can cause injury. xx0900000815 Extended rotation This axis has extended rotation (working area) compared to standard. xx0900000814 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page 20 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.2.2 Safety symbols on manipulator labels Continued Symbol Description Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 1300 21 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.2.2 Safety symbols on manipulator labels Continued Symbol Description Heat Risk of heat that can cause burns. (Both signs are used) xx0900000818 3HAC 4431-1/06 ! xx1300001087 4 3 5 Moving robot The robot can move unexpectedly. 6 2 1 xx0900000819 xx1000001141 4 2 3 1 xx1500002616 Continues on next page 22 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.2.2 Safety symbols on manipulator labels Continued Symbol Description Brake release buttons xx0900000820 xx1000001140 Lifting bolt xx0900000821 Chain sling with shortener xx1000001242 Lifting of robot xx0900000822 Oil Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 1300 23 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.2.2 Safety symbols on manipulator labels Continued Symbol Description No mechanical stop xx1000001144 Stored energy Warns that this part contains stored energy. Used in combination with Do not disassemble symbol. xx0900000825 Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level. xx0900000826 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 24 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.3 Robot stopping functions 1.3 Robot stopping functions Protective stop and emergency stop The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - OmniCore C30 • Product manual - OmniCore C90XT • Product manual - OmniCore E10 Reasons for selection of emergency stop category in IRB 1300-12/1.4 The emergency stop shall function either as a category 0 stop or as a category 1 stop. The selection of the emergency stop category depends on the risk assessment results of the robot. For emergency stop in IRB 1300-12/1.4, a category 1 stop is defined as default. Exceptions are only allowed when there is a technical fault in the system. Category 1 emergency stop is used otherwise because: • Stopping using the motor produces repeatable stopping distances (no variation of brake friction coefficient). • Stopping using the motor produces the shortest stopping distance without any risk of overloading structural components (pre-defined braking torque, no delay), and, minimizes the forces applied by robot. • Stopping using the motor saves on brake wear, so that the brake can perform its primary (holding) function for longer. Because of these reasons, the end user/system integrator should always use a category 1 emergency stop for IRB 1300-12/1.4 in the application risk assessment, with category 0 emergency stop still being configurable in settings of external/local emergency stop. Product manual - IRB 1300 25 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.4 Safety during installation and commissioning 1.4 Safety during installation and commissioning National or regional regulations The integrator of the robot system is responsible for the safety of the robot system. The integrator is responsible that the robot system is designed and installed in accordance with the safety requirements set forth in the applicable national and regional standards and regulations. The integrator of the robot system is required to perform a risk assessment. Layout The robot integrated to a robot system shall be designed to allow safe access to all spaces during installation, operation, maintenance, and repair. If robot movement can be initiated from an external control panel then an emergency stop must also be available. If the manipulator is delivered with mechanical stops, these can be used for reducing the working space. A perimeter safeguarding, for example a fence, shall be dimensioned to withstand the following: • The force of the manipulator. • The force of the load handled by the robot if dropped or released at maximum speed. • The maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot. The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator. Consider exposure to hazards, such as slipping, tripping, and falling. Hazards due to the working position and posture for a person working with or near the robot shall be considered. Hazards due to noise emission from the robot needs to be considered. Consider hazards from other equipment in the robot system, for example, that guards remain active until identified hazards are reduced to an acceptable level. Allergenic material See Environmental information on page 748 for specification of allergenic materials in the product, if any. Securing the robot to the foundation The robot must be properly fixed to its foundation/support, as described in the respective product manual. When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page 26 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.4 Safety during installation and commissioning Continued Electrical safety Incoming mains must be installed to fulfill national regulations. The power supply wiring to the robot must be sufficiently fused and if necessary, it must be possible to disconnect it manually from the mains power. The power to the robot must be turned off with the main switch and the mains power disconnected when performing work inside the controller cabinet. Lock and tag shall be considered. Harnesses between controller and manipulator shall be fixed and protected to avoid tripping and wear. Wherever possible, power on/off or rebooting the robot controller shall be performed with all persons outside the safeguarded space. Note Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot. Safety devices The integrator is responsible for that the safety devices necessary to protect people working with the robot system are designed and installed correctly. When integrating the robot with external devices to a robot system: • The integrator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards. • The integrator of the robot system must ensure that safety functions are interlocked in accordance with applicable standards. Other hazards A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. The risk assessment should also consider other hazards arising from the application, such as, but not limited to: • Water • Compressed air • Hydraulics End-effector hazards require particular attention for applications which involve close human collaboration with the robot. Verify the safety functions Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 1300 27 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.5 Safety during operation 1.5 Safety during operation Automatic operation Verify the application in the operating mode manual reduced speed, before changing mode to automatic and initiating automatic operation. Unexpected movement of robot arm WARNING Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. 28 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.6.1 Safety during maintenance and repair 1.6 Safety during maintenance and repair 1.6.1 Safety during maintenance and repair General Corrective maintenance must only be carried out by personnel trained on the robot. Maintenance or repair must be done with all electrical, pneumatic, and hydraulic power switched off, that is, no remaining hazards. Hazards due to stored mechanical energy in the manipulator for the purpose of counterbalancing axes must be considered before maintenance or repair. Never use the robot as a ladder, which means, do not climb on the controller, manipulator, including motors, or other parts. There are hazards of slipping and falling. The robot might be damaged. Make sure that there are no loose screws, turnings, or other unexpected parts remaining after work on the robot has been performed. When the work is completed, verify that the safety functions are working as intended. Hot surfaces Surfaces can be hot after running the robot, and touching these may result in burns. Allow the surfaces to cool down before maintenance or repair. Allergic reaction Warning Description Elimination/Action When working with lubricants Make sure that protective gear there is a risk of an allergic reac- like goggles and gloves are altion. ways worn. Allergic reaction Gearbox lubricants (oil or grease) When handling oil, grease, or other chemical substances the safety information of the respective manufacturer must be observed. Note Take special care when handling hot lubricants. Warning Description Elimination/Action Changing and draining gearbox Make sure that protective gear oil or grease may require hand- like goggles and gloves are alling hot lubricant heated up to ways worn during this activity. 90 °C. Hot oil or grease Continues on next page Product manual - IRB 1300 29 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.6.1 Safety during maintenance and repair Continued Warning Description Elimination/Action When working with lubricants Make sure that protective gear there is a risk of an allergic reac- like goggles and gloves are altion. ways worn. Allergic reaction Possible pressure build-up in gearbox Do not overfill Specified amount depends on drained volume 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. Overfilling of gearbox lubricant can lead to internal over-pressure inside the gearbox which in turn may: • damage seals and gaskets • completely press out seals and gaskets • prevent the robot from moving freely. Make sure not to overfill the gearbox when filling it with oil or grease. After filling, verify that the level is correct. The specified amount of oil or After filling, verify that the level grease is based on the total is correct. volume of the gearbox. When changing the lubricant, the amount refilled may differ from the specified amount, depending on how much has previously been drained from the gearbox. For lifetime reasons always drain as much oil as possible from the gearbox. The magnetic oil plugs will gather residual metal chips. Contaminated oil in gearboxes Hazards related to batteries Under rated conditions, the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside. There is a hazard in case of abuse (mechanical, thermal, electrical) which leads to the activation of safety valves and/or the rupture of the battery container. As a result under certain circumstances, electrolyte leakage, electrode materials reaction with moisture/water or battery vent/explosion/fire may follow. 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 Operating conditions, robot on page 39. See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Continues on next page 30 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.6.1 Safety during maintenance and repair Continued Unexpected movement of robot arm WARNING Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRB 1300 31 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.6.2 Emergency release of the robot axes 1.6.2 Emergency release of the robot axes Description In an emergency situation, the brakes on a robot axis can be released manually by pushing a brake release button. How to release the brakes is described in the section: • Manually releasing the brakes on page 65. 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 manipulator does not result in additional hazards, for example, even more severe injuries on a trapped person. 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. 32 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.6.3 Brake testing 1.6.3 Brake testing When to test During operation, the holding brake of each axis normally wears down. A test can be performed to determine whether the brake can still perform its function. How to test The function of the holding brake of each axis motor may be verified as described below: 1 Run each axis to a position where the combined weight of the manipulator 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 manipulator does not change position as the motors are switched off, then the brake function is adequate. Note It is recommended to run the service routine BrakeCheck as part of the regular maintenance, see the operating manual for the robot controller. For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page 10. Product manual - IRB 1300 33 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.7 Safety during troubleshooting 1.7 Safety during troubleshooting General When troubleshooting requires work with power switched on, special considerations must be taken: • Safety circuits might be muted or disconnected. • Electrical parts must be considered as live. • The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards. WARNING Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation, operation, maintenance, and repair. 34 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 1 Safety 1.8 Safety during decommissioning 1.8 Safety during decommissioning General See section Decommissioning on page 747. Unexpected movement of robot arm WARNING Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 1300 35 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. This page is intentionally left blank 2 Technical data 2.1 Technical data 2 Technical data 2.1 Technical data Weight, robot The table shows the weight of the robot. Robot model Nominal weight IRB 1300 IRB 1300-11/0.9: 75 kg IRB 1300-10/1.15: 77 kg IRB 1300-7/1.4: 79 kg IRB 1300-12/1.4: 79 kg Note The weight does not include additional options, tools and other equipment fitted on the robot. Loads on foundation, robot The illustration shows the directions of the robots stress forces. The directions are valid for all floor mounted, suspended and wall mounted robots. Txy Fz Fxy Tz xx1100000521 Fxy Force in any direction in the XY plane Fz Force in the Z plane Txy Bending torque in any direction in the XY plane Tz Bending torque in the Z plane Continues on next page Product manual - IRB 1300 37 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.1 Technical data Continued The table shows the various forces and torques working on the robot during different kinds of operation. Note These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time! WARNING The robot installation is restricted to the mounting options given in following load table(s). Floor mounted Force Endurance load (in operation) Maximum load (emergency stop) Force xy ±821 N ±2186 N Force z 428 N±1000 N 1547 N±1000 N Torque xy ±814 Nm ±2392 Nm Torque z ±236 Nm ±583 Nm Force Endurance load (in operation) Max. load (emergency stop) Force xy ±1478 N ±2860 N Force z ±288 N ±963 N Torque xy ±1068 Nm ±2741 Nm Torque z ±352 Nm ±863 Nm Force Endurance load (in operation) Max. load (emergency stop) Force xy ±821 N ±2186 N Force z 428 N±1000 N 1547 N±1000 N Torque xy ±814 Nm ±2392 Nm Torque z ±236 Nm ±583 Nm Wall mounted Suspended Continues on next page 38 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.1 Technical data Continued Requirements, foundation The table shows the requirements for the foundation where the weight of the installed robot is included: Requirement Value Flatness of foundation 0.1/500 mm surface Maximum tilt 5° Minimum resonance frequency 22 Hz Note Flat foundations give better repeatability of the 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. The value is recommended for optimal performance. Due to foundation stiffness, consider robot mass Note including equipment. i It may affect the For information about compensating for foundamanipulator life- tion flexibility, see Application manual - Controltime to have a ler software OmniCore, section Motion Process lower resonance Mode. frequency than recommended. Minimum foundation 150 MPa material yield strength 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 frequency. The robot should be mounted as rigid as possibly to the floor. Disturbances from other machinery will affect the robot and the tool accuracy. The robot has resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified, although somewhat damped by the servo control. This might be a problem, depending on the requirements from the applications. If this is a problem, the robot needs to be isolated from the environment. Storage conditions, robot The table shows the allowed storage conditions for the robot: Parameter Value Minimum ambient temperature -25°C (-13°F) Maximum ambient temperature +55°C (+131°F) Maximum ambient temperature (less than 24 hrs) +70°C (+158°F) Maximum ambient humidity 95% at constant temperature (gaseous only) Operating conditions, robot The table shows the allowed operating conditions for the robot: Parameter Value Minimum ambient temperature +5°C i (41°F) Maximum ambient temperature +45°C (113°F) Continues on next page Product manual - IRB 1300 39 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.1 Technical data Continued Parameter Value Maximum ambient humidity 95% at constant temperature i At low environmental temperature (below 10° C) a warm-up phase is recommended to be run with the robot. Otherwise there is a risk that the robot stops or runs with lower performance due to temperature dependent oil and grease viscosity. Protection classes, robot The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class i Manipulator, protection type Standard IP40 IP67 (option 3350-670) Manipulator, protection type Foundry Plus 2 IP67 Manipulator, protection type Clean Room ISO 4, IP54 i According to IEC 60529. Environmental information The product complies with IEC 63000. Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances. 40 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.2 Dimensions 2.2 Dimensions Main dimensions of IRB 1300-11/0.9 50 515 A 90 544 1009 1069 425 40 425 240,6 340 190 220 126,8 62,5 190 B 190 21 118 80 170 189 190 96 R101,5 xx1900001331 Pos Description A Turning radius: R84 B Turning radius: R207 Continues on next page Product manual - IRB 1300 41 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.2 Dimensions Continued Main dimensions of IRB 1300-10/1.15 515 150 90 A 544 1159 1219 575 40 425 240,6 62,5 126,8 340 190 220 190 B 190 21 118 80 170 189 190 96 R101,5 xx1900001332 Pos Description A Turning radius: R84 B Turning radius: R282 Continues on next page 42 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.2 Dimensions Continued Main dimensions of IRB 1300-7/1.4 and IRB 1300-12/1.4 765 150 90 A 544 1159 1219 575 40 675 240,6 62,5 340 190 220 190 B 190 21 118 80 170 189 190 96 R101,5 xx1900001333 Pos Description A Turning radius: R84 B Turning radius: R282 Product manual - IRB 1300 43 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.3 Working range 2.3 Working range Illustration, working range IRB 1300-11/0.9 This illustration shows the unrestricted working range of the robot. 1395.9 Pos 1 Pos 9 Pos 6 Pos 2 Pos 7 Pos 3 Pos 8 Pos 5 156.1 Pos 4 801.9 901.9 xx1900001334 Positions at wrist center and angle of axes 2 and 3 Position in the figure Positions at wrist center (mm) Angle (degrees) X Z axis 2 axis 3 pos0 475 1009 0° 0° pos1 50 1,395.9 0° -84.6° pos2 265.9 600.7 0° 65° pos3 901.9 544 90° -84.6° pos4 702.6 -3.6 130° -84.6° pos5 -64.7 170.3 -100° -210° pos6 -43.3 746.7 -100° 65° pos7 -801.9 544 -90° -84.6° pos8 -788.9 396.1 -100° -84.6° pos9 410 696.3 130° -210° Continues on next page 44 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.3 Working range Continued Illustration, working range IRB 1300-10/1.15 This illustration shows the unrestricted working range of the robot. Pos 1 Pos 6 Pos 3 Pos 7 1545.9 Pos 2 Pos 8 Pos 9 403.99 Pos 5 Pos 4 851.9 1151.9 xx1900001335 Positions at wrist center and angle of axes 2 and 3 Position in the figure Positions at wrist center (mm) Angle (degrees) X Z axis 2 axis 3 pos0 575 1159 0° 0° pos1 150 1,545.9 0° -84.6° pos2 365.9 750.7 0° 65° pos3 1,151.9 544 90° -84.6° pos4 573.4 -364 155° -84.6° pos5 -146.3 168.7 -95° -210° pos6 -74.8 741 -95° 65° pos7 -851.9 544 -90° -84.6° pos8 -848.1 456.9 -95° -84.6° pos9 604 394 155° -210° Continues on next page Product manual - IRB 1300 45 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.3 Working range Continued Illustration, working range IRB 1300-7/1.4 This illustration shows the unrestricted working range of the robot. 1795.2 Pos 1 Pos 6 Pos 9 Pos 7 Pos 3 Pos 2 Pos 8 653.35 Pos 5 Pos 4 1101.2 1401.2 xx1900001336 Positions at wrist center and angle of axes 2 and 3 Position in the figure Positions at wrist center (mm) Angle (degrees) X Z axis 2 axis 3 pos0 825 1159 0° 0° pos1 150 1,795.2 0° -86.6° pos2 429.2 503.2 0° 69° pos3 1,401.2 544 90° -86.6° pos4 678.8 -590 155° -86.6° pos5 -2.9 -36.1 -95° -210° pos6 166.3 825.7 -95° 69° pos7 -1,101.2 544 -90° -86.6° pos8 -1,096.4 435 -95° -86.6° pos9 747.4 598.7 155° -210° Continues on next page 46 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.3 Working range Continued Illustration, working range IRB 1300-12/1.4 This illustration shows the unrestricted working range of the robot. 1795.2 Pos 1 Pos 6 Pos 9 Pos 7 Pos 3 Pos 2 Pos 8 653.35 Pos 5 Pos 4 1101.2 1401.2 xx1900001336 Positions at wrist center and angle of axes 2 and 3 Position in the figure Positions at wrist center (mm) Angle (degrees) X Z axis 2 axis 3 pos0 825 1159 0° 0° pos1 150 1,795.2 0° -86.6° pos2 429.2 503.2 0° 69° pos3 1,401.2 544 90° -86.6° pos4 678.8 -590 155° -86.6° pos5 -2.9 -36.1 -95° -210° pos6 166.3 825.7 -95° 69° pos7 -1,101.2 544 -90° -86.6° pos8 -1,096.4 435 -95° -86.6° pos9 747.4 598.7 155° -210° Continues on next page Product manual - IRB 1300 47 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.3 Working range Continued Top view of working range R1401.2 (IRB 1300-7/1.400 and -12/1.400 ) R1151.9 (IRB 1300-10/1.150) 18 0° R901.9 (IRB 1300-11/0.900) R298.89 (IRB 1300-10/1.150) 0° 18 R282.17 (IRB 1300-7/1.400 and -12/1.400) R223.22 (IRB 1300-11/0.900) xx1900001341 R282 (IRB 1300-7/1.400, -12/1.400 and -10/1.150) (A) R207 (IRB 1300-11/0.900) (A) xx1900001342 Working range Axis Working range Note Axis 1 ±180° Wall mounted robot has a work area for axis 1 that depends on payload and the positions of other axes. Simulation in RobotStudio is recommended. Axis 2 IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4 -95°/+155° IRB 1300-11/0.9 -100°/+130° Axis 3 IRB 1300-7/1.4 and IRB 1300-12/1.4 -210°/+69° IRB 1300-10/1.15 and IRB 1300-11/0.9 -210°/+65° Axis 4 ±230° Continues on next page 48 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.3 Working range Continued Axis Working range Axis 5 ±130° Axis 6 ±400° Default value. ±242 Maximum revolution value. The default working range for axis 6 can be extended by changing parameter values in the software. Product manual - IRB 1300 Note 49 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 2 Technical data 2.4 The unit is sensitive to ESD 2.4 The unit is sensitive to ESD Description ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges. This discharge may destroy sensitive electronics. Safe handling Use one of the following alternatives: • Use a wrist strap. Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly. • Use an ESD protective floor mat. The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. 50 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.1 Introduction to installation and commissioning 3 Installation and commissioning 3.1 Introduction to installation and commissioning General This chapter contains assembly instructions and information for installing the IRB 1300 at the working site. See also the product manual for the robot controller. The installation must be done by qualified installation personnel in accordance with the safety requirements set forth in the applicable national and regional standards and regulations. Safety information Before any installation work is commenced, all safety information must be 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 15 before performing any installation work. Note Always connect the IRB 1300 and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. For more information see: • Product manual - OmniCore C30 • Product manual - OmniCore C90XT • Product manual - OmniCore E10 Product manual - IRB 1300 51 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.2.1 Pre-installation procedure 3.2 Unpacking 3.2.1 Pre-installation procedure Introduction This section is intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • Be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work. • Conform to all national and local codes. Checking the pre-requisites for installation Action 1 Make a visual inspection of the packaging and make sure that nothing is damaged. 2 Remove the packaging. 3 Check for any visible transport damage. Note Stop unpacking and contact ABB if transport damages are found. 4 Clean the unit with a lint-free cloth, if necessary. 5 Make sure that the lifting accessory used (if required) is suitable to handle the weight of the robot as specified in: Weight, robot on page 37 6 If the robot is not installed directly, it must be stored as described in: Storage conditions, robot on page 39 7 Make sure that the expected operating environment of the robot conforms to the specifications as described in: Operating conditions, robot on page 39 8 Before taking the robot to its installation site, make sure that the site conforms to: • Loads on foundation, robot on page 37 • Protection classes, robot on page 40 • Requirements, foundation on page 39 9 Before moving the robot, please observe the stability of the robot: Risk of tipping/stability on page 53 10 When these prerequisites are met, the robot can be taken to its installation site as described in section: On-site installation on page 58 11 Install required equipment, if any. 52 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.2.2 Risk of tipping/stability 3.2.2 Risk of tipping/stability Risk of tipping If the robot is not fastened to the foundation while moving the arm, the robot is not stable in the whole working area. Moving the arm will displace the center of gravity, which may cause the robot to tip over. The shipping position is the most stable position. Do not change the robot position before securing it to the foundation! Shipping and transportation position This figure shows the robot in its shipping position and transportation position. IRB 1300-11/0.9 IRB 1300-10/1.15 IRB 1300-7/1.4 and IRB 1300-12/1.4 ° 81 21 ° 40 ° ° 73 ° 50 ° 52 ° 25 25° 41° xx1900001578 xx1900001576 xx1900001577 Axis Angle -11/0.9 -10/1.15 -7/1.4 and -12/1.4 1 0° 0° 0° 2 -25° -41° -52° 3 65° 50° 69° 4 0° 0° 0° 5 50° 81° 73° 6 0° 0° 0° Transportation bracket At delivery, the robot is locked in the correct position with a transportation bracket for securing the position during shipping and transport. The bracket must be removed before conducting any service work. Continues on next page Product manual - IRB 1300 53 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.2.2 Risk of tipping/stability Continued How to use the transportation bracket is described further in Transportation bracket on page 56. WARNING The robot is likely to be mechanically unstable if not secured to the foundation. 54 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.2.3 Extra O-rings 3.2.3 Extra O-rings Installation of extra O-rings For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) An extra O-ring is delivered together with the robot and must be fitted to the robot during installation. Equipment Article number Note O-ring 3HAB3772-19 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used to seal between the main power cable and connector. Robots with manipulator cables routed from the rear of the base: xx2000002338 Robots with manipulator cables routed from below (3309-1): xx2000002339 Further information For installation information, see On-site installation on page 58 and Electrical connections on page 90. Product manual - IRB 1300 55 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.2.4 Transportation bracket 3.2.4 Transportation bracket Location of the transportation bracket At delivery, the robot is locked in the correct position with a transportation bracket for securing the position during shipping and transport. The bracket must be removed before conducting any service work and must be refitted before shipping and transportation. IRB 1300-11/0.9 IRB 1300-10/1.15 IRB 1300-7/1.4 and IRB 1300-12/1.4 xx1900001528 xx1900001526 xx1900001527 Removing the transportation bracket Action Note 1 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 56 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.2.4 Transportation bracket Continued Action 2 Note Remove the screws and washers. xx1900001529 xx1900001530 3 Remove the bracket. The transportation bracket of IRB 1300-11/0.9 is used as an example. xx1900001531 Product manual - IRB 1300 57 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.1.1 Lifting the robot with roundslings 3.3 On-site installation 3.3.1 Lifting the robot 3.3.1.1 Lifting the robot with roundslings Illustration - attaching the roundslings 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 56. IRB 1300-11/0.9 IRB 1300-10/1.15 IRB 1300-7/1.4 and IRB 1300-12/1.4 xx1900001581 xx1900001580 xx1900001579 DANGER Attempting to lift a robot in any other position than the recommended lifting position may result in the robot tipping over, causing severe damage or injury. Continues on next page 58 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.1.1 Lifting the robot with roundslings Continued Required tools and equipment Equipment Article number Note Overhead crane - Roundsling, 0.8 m - Length: 0.8 m Lifting capacity: >400 kg Roundsling, 1.7 m - Length: 1.7 m Lifting capacity: >400 kg Lifting accessory, robot 3HAC077885-001 Includes lifting accessories, lifting beam and screws. Continues on next page Product manual - IRB 1300 59 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.1.1 Lifting the robot with roundslings Continued Lifting the robot with roundslings Use this procedure to lift the robot with roundslings . Action 1 Note Valid for IRB 1300-11/0.9 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: -25° • Axis 3: 65° • Axis 4: 0° • Axis 5: 50° • Axis 6: 0° ° WARNING 50 The robot is mechanically unstable if not secured to the foundation. ° 25 25° xx1900001576 Valid for IRB 1300-10/1.15 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: -41° • Axis 3: 50° • Axis 4: 0° • Axis 5: 81° • Axis 6: 0° ° ° 81 40 2 WARNING The robot is mechanically unstable if not secured to the foundation. 41° xx1900001577 3 Valid for IRB 1300-7/1.4 and IRB 1300-12/1.4 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: -52° • Axis 3: 69° • Axis 4: 0° • Axis 5: 73° • Axis 6: 0° Continues on next page 60 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.1.1 Lifting the robot with roundslings Continued Action Note WARNING The robot is mechanically unstable if not secured to the foundation. ° 21 ° 73 ° 52 xx1900001578 4 Fit the lifting tools to the robot. Use the enclosed screws. Lifting accessory, robot: 3HAC077885001 Tightening torque: 15 Nm xx1900001594 5 Fit the roundslings to the lifting tools and attach Make sure the roundsling has free them to the lifting beam. space and does not wear against any part of the robot. Roundsling, 1.7 m xx1900001595 Continues on next page Product manual - IRB 1300 61 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.1.1 Lifting the robot with roundslings Continued 6 Action Note Fit the roundslings to the lifting beam and to the overhead crane. Roundsling, 0.8 m xx1900001579 7 CAUTION The weight of the IRB 1300 robot is IRB 1300-11/0.9: 75 kg IRB 1300-10/1.15: 77 kg IRB 1300-7/1.4: 79 kg IRB 1300-12/1.4: 79 kg All lifting accessories used must be sized accordingly. 8 WARNING Personnel must not, under any circumstances, be present under the suspended load. 9 Raise the overhead crane to lift the robot. Continues on next page 62 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.1.1 Lifting the robot with roundslings Continued Action 10 Note If the manipulator should be mounted on a wall, or in an suspended position the manipulator can now be tilted slowly by hand. xx1900001596 Product manual - IRB 1300 63 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.1.2 Lifting and rotating a suspended mounted manipulator 3.3.1.2 Lifting and rotating a suspended mounted manipulator 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 lifting accessory. Article numbers for the accessory and the instruction is specified in Special tools on page 760. 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. Illustration xx1900001596 64 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.2 Manually releasing the brakes 3.3.2 Manually releasing the brakes Introduction to manually releasing the brakes This section describes how to release the holding brakes for the axes motors. Location of the brake release unit The brake release unit is located as shown in the figure. xx1900001653 Releasing the brakes This procedure describes how to release the holding brakes when the robot is equipped with a brake release unit. Action Note 1 Note If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to the section Supplying power to connector R1.MP on page 66. 2 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. Continues on next page Product manual - IRB 1300 65 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.2 Manually releasing the brakes Continued Action 3 Note The brake will be enable as soon as the button is released. xx1900001653 Supplying power to connector R1.MP If the robot is not connected to the controller, power must be supplied to connector R1.MP on the robot, in order to enable the brake release buttons. Action Note 1 DANGER Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously and instantly! 2 Supply • 0V on pin 12. • 24V on pin 11. Note Do not interchange the 24V and 0V pins. If they are mixed up, damage can be caused to internal electrical components. xx1900001654 3 Use the brake releasing button as described in Releasing the brakes on page 65. 66 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.3 Orienting and securing the robot 3.3.3 Orienting and securing the robot General This section describes how to orient and secure the robot to the base plate or foundation in order to run the robot safely. Attachment screws The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate/foundation. Suitable screws M16x50 Quantity 4 pcs Quality 8.8 Suitable washer 17 x 30 x 3, steel hardness class 200HV Guide pins 2 pcs, D10x30, ISO 2338 - 10m6x30 - A1 Tightening torque 150 Nm±10 Nm Length of thread engagement Minimum 19 mm for ground with material yield strength 150 MPa Level surface requirements 0.1/500 mm Installation of extra O-rings For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Continues on next page Product manual - IRB 1300 67 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.3 Orienting and securing the robot Continued An extra O-ring is delivered together with the robot and must be fitted to the robot during installation. Equipment Article number Note O-ring 3HAB3772-19 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used to seal between the main power cable and connector. Robots with manipulator cables routed from the rear of the base: xx2000002338 Robots with manipulator cables routed from below (3309-1): xx2000002339 Securing a floor mounted robot Use this procedure to orient and secure the robot floor mounted. Action Note 1 Make sure the installation site for the robot conforms to the specifications in section Technical data on page 37. 2 Prepare the installation site with attachment holes. The hole configuration of the base is shown in the figure in Hole conThe foundation surface must be clean and unfiguration, base on page 70. painted. 3 CAUTION The weight of the IRB 1300 robot is IRB 1300-11/0.9: 75 kg IRB 1300-10/1.15: 77 kg IRB 1300-7/1.4: 79 kg IRB 1300-12/1.4: 79 kg All lifting accessories used must be sized accordingly. Continues on next page 68 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.3 Orienting and securing the robot Continued Action Note 4 CAUTION When the robot is put down after being lifted or transported, there is a risk of it tipping, if not properly secured. 5 Lift the robot. See Lifting the robot on page 58. 6 Fit two pins to the holes in the base. 2 pcs, D10x30, ISO 2338 - 10m6x30 - A1 7 Guide the robot gently, using the attachment Make sure the robot base is corscrews while lowering it into its mounting position. rectly fitted onto the pins. 8 Fit the securing screws and washers in the attach- Screws: M16x50, 4 pcs, quality 8.8 ment holes of the base. Washers: 17 x 30 x 3, steel hardness class 200HV 9 Tighten the bolts in a crosswise pattern to ensure Tightening torque: 150 Nm±10 Nm that the base is not distorted. 10 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Fit the O-ring 3HAB3772-19 to the main power connector on the robot base. Robots with manipulator cables routed from the rear of the base: xx2000002338 Robots with manipulator cables routed from below (3309-1): xx2000002339 Continues on next page Product manual - IRB 1300 69 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.3 Orienting and securing the robot Continued Hole configuration, base This illustration shows the hole configuration used when securing the robot. 190 73 73 0. 5 A 10 H7 +0.015 0 100 190 Detail A 0. 5 100 0.08 B H7 +0.015 0 18.5 10 0.2 B 0.08 22 Section B 190 21 118 80 170 189 190 96 R101,5 xx1900001337 70 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.4 Setting the system parameters for an inverted or a tilted robot 3.3.4 Setting the system parameters for an inverted or a tilted robot General The robot is configured for mounting parallel to the floor, without tilting, on delivery. The method for mounting the robot in a inverted (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 inverted 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 39. System parameters Note The mounting angle must be configured correctly in the system parameters so that the robot system can control the movements in the best possible way. An incorrect definition of the mounting angle will result in: • Overloading the mechanical structure. • Lower path performance and path accuracy. • Some functions will not work properly, for example Load Identification and Collision detection. Gravity Beta When the robot is mounted other than floor-standing (rotated around the y-axis), the robot base frame and the system parameter Gravity Beta must be redefined. If the robot is mounted upside down (inverted), then Gravity Beta should be π (+3.141593). If the robot is mounted on a wall, then Gravity Beta should be ±π/2 (±1.570796). 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). Continues on next page Product manual - IRB 1300 71 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.4 Setting the system parameters for an inverted or a tilted robot Continued The Gravity Alpha is a positive rotation direction around the x-axis in the base coordinate system. The value is set in radians. Note The system parameter Gravity Alpha is not supported for all robot types. If the robot does not support Gravity Alpha, then use Gravity Beta along with the re-calibration of axis 1 to define the rotation of the robot around the x-axis. Note The parameter is supported for all robots on track when the system parameter 7 axes high performance motion is set, see Technical reference manual - System parameters. Gamma Rotation Gamma Rotation defines the orientation of the robot foot on the travel carriage (track motion). Mounting angles and values The parameter Gravity Beta (or Gravity Alpha) specifies the mounting angle of the robot in radians. It is calculated in the following way. Gravity Beta = A° x 3.141593/180 = B radians, where A is the mounting angle in degrees and B is the mounting angle in radians. Example of position Mounting angle (A°) Gravity Beta Floor mounted 0° 0.000000 (Default) Wall mounted 90° 1.570796 Inverted mounting 180° 3.141593 Examples of mounting angles tilted around the X axis (Gravity Alpha) The following illustration shows the IRB 120, but the same principle applies for all robots. 0° xx2100000297 Continues on next page 72 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.4 Setting the system parameters for an inverted or a tilted robot Continued xx2100000299 xx2100000300 Mounting angle Gravity Alpha 0° (Floor mounted) 0 90° (Wall) 1.570796 -90° (Wall) -1.570796 Note For suspended robots (180°), it is recommended to use Gravity Beta instead of Gravity Alpha. Limitations in working area If mounting the robot on a wall, the working range of axis 1 is limited. These limitations are specified in the table Working range on page 48. Defining the system parameters in RobotWare The value of the system parameters that define the mounting angle must be redefined when changing the mounting angle of the robot. The parameters belong to the type Robot, in the topic Motion. The system parameters are described in Technical reference manual - System parameters. The system parameters are configured in RobotStudio or on the FlexPendant. Product manual - IRB 1300 73 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.5 Loads fitted to the robot, stopping time and braking distances 3.3.5 Loads fitted to the robot, stopping time and braking distances Define loads carefully 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. Load diagrams, permitted extra loads (equipment) and their positions are specified in the product specification. The loads must be defined in the software. Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot. See Product specification - Robot stopping distances according to ISO 10218-1. 74 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) 3.3.6 Fitting equipment on the robot (robot dimensions) Robot dimensions The figure shows the dimension of the robot. Main dimensions of IRB 1300-11/0.9 50 515 A 90 544 1009 1069 425 40 425 240,6 340 190 220 126,8 62,5 190 B 190 21 118 80 170 189 190 96 R101,5 xx1900001331 Pos Description A Turning radius: R84 B Turning radius: R207 Continues on next page Product manual - IRB 1300 75 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) Continued Main dimensions of IRB 1300-10/1.15 515 150 90 A 544 1159 1219 575 40 425 240,6 62,5 126,8 340 190 220 190 B 190 21 118 80 170 189 190 96 R101,5 xx1900001332 Pos Description A Turning radius: R84 B Turning radius: R282 Continues on next page 76 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) Continued Main dimensions of IRB 1300-7/1.4 and IRB 1300-12/1.4 765 150 90 A 544 1159 1219 575 40 675 240,6 62,5 340 190 220 190 B 190 21 118 80 170 189 190 96 R101,5 xx1900001333 Pos Description A Turning radius: R84 B Turning radius: R282 Continues on next page Product manual - IRB 1300 77 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) Continued Attachment holes and dimensions Extra loads can be mounted on robot. 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. Maximum allowed arm load depends on center of gravity of arm load and robot payload. 87.5 62.5 150 100 50 87.5 xx1900001599 Variant Max. armload (kg) IRB 1300-11/0.9 1 IRB 1300-10/1.15 0.5 IRB 1300-7/1.4 0.5 IRB 1300-12/1.4 0.5 Continues on next page 78 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) Continued Holes for fitting extra equipment The robot is supplied with holes for fitting extra equipment, as shown in the following figures 65 C (4x)M4x8 C B (4x)M4x8 40 B (4x)M10x15 A 125 A xx1900001338 Continues on next page Product manual - IRB 1300 79 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) Continued E F 20 (2x)M4x6 F (2x)M4x8 60 D E (2x)M5x10 40 D xx1900001339 Continues on next page 80 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) Continued Tool flange standard For robots with protection classes IP40 and IP67, and with protection type Clean Room 0 50 h7 -0,025 +0,021 25 H7 0 6 G O 03 +0,015 6 H7 0 0.04 SECTION H-H (4)x9 5° 0° 13 4xM6 P 9 9 0.2 P 40 30 ° DETAIL G IRB1300 IP40/IP67/CR +0,012 5 H7 0 0.04 6 xx1900001340 For robots with protection type Foundry Plus +0.021 0 8 25 H7 L 6 H7 SECTION N-N +0.012 9 0 6.5 2 0.04 ° 45 45 ° 4xM6 9 6.5 2 0.2 02 5 H7 0.04 45 30 6 N ° ° 60 DETAIL L IRB1300 Foundry 40 +0.012 0 6 2 ° 45° N xx2100000705 Continues on next page Product manual - IRB 1300 81 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.6 Fitting equipment on the robot (robot dimensions) Continued Fastener quality When fitting tools on the tool flange, only use screws with quality 12.9. For other equipment use suitable screws and tightening torque for your application. 82 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.7 Installation of signal lamp (option) 3.3.7 Installation of signal lamp (option) Description A signal lamp with a yellow fixed light can be mounted in the cell or any other visible location, and driven by I/O signal or MON_LAMP signal from the controller. Function The lamp is active in MOTORS ON mode. Installation of signal lamp from I/O signal Action 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 For robots with OmniCore C line Connect the lamp cable connector to the local I/O connector on the controller. Note The local I/O connectors provides 16 digital output signals for use. 3 For robots with OmniCore E line Connect the lamp cable connector to the I/O connector on the controller. Note The I/O connectors provides 8 digital output signals for use. 4 Configure the lamp by adding a System Output type signal with status set to Motors On State. 5 The lamp is now ready for use and is lit in MOTORS ON mode. Installation of signal lamp from MON_LAMP signal Action 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 For robots with OmniCore C line Connect the lamp cable connector to the X15 connector on the controller. Note The X15 connector provides MON_LAMP output signals for use. For more details, see chapter Descriptions for connectors in OmniCore product manuals. Continues on next page Product manual - IRB 1300 83 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.3.7 Installation of signal lamp (option) Continued Action 3 For robots with OmniCore E line Connect the lamp cable connector to the MON connector on the controller. Note The MON connector provides MON_LAMP output signals for use. For more details, see chapter Descriptions for connectors in OmniCore product manuals. 4 The lamp is now ready for use and is lit in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller. Further information about how to set up I/O system may be found in Technical reference manual - System parameters. 84 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.4.1 Adjusting the working range 3.4 Restricting the working range 3.4.1 Adjusting the working range Reasons for adjusting the manipulator working range The working range of each manipulator axis is configured in the software. If there is a risk that the manipulator may collide with other objects at installation site, its working space should be limited. The manipulator must always be able to move freely within its entire working space. Working range configurations The parameter values for the axes working range can be altered within the allowed working range and according to available options for the robot, either to limit or to extend a default working range. Allowed working ranges and available options for each manipulator axis are specified in Working range on page 48. Mechanical stops on the manipulator Mechanical stops are and can be installed on the manipulator as limiting devices to ensure that the manipulator axis does not exceed the working range values set in the software parameters. Note The mechanical stops are only installed as safety precaution to physically stop the robot from exceeding the working range set. A collision with a mechanical stop always requires actions for repair and troubleshooting. Axis Fixed mechanical stop i Movable mechanical stop ii Axis 1 yes no Axis 2 yes no Axis 3 yes no Axis 4 yes no Axis 5 yes no Axis 6 no no i ii Part of the casting or fixed on the casting and can not /should not be removed. Can be installed in one or more than one position, to ensure a reduced working range, or be removed to allow extended working range. Product manual - IRB 1300 85 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.4.2 Mechanically restricting the working range 3.4.2 Mechanically restricting the working range Location of mechanical stops Axis 1 xx2000000406 A Mechanical stop, axis 1, slider B Mechanical stop, axis 1, fixed block Axis 2 xx2000000407 Continues on next page 86 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.4.2 Mechanically restricting the working range Continued Axis 3 IRB 1300-11/0.9, IRB 1300-7/1.4 and IRB 1300-12/1.4 IRB 1300-10/1.15 xx2000000408 xx2000000471 Axis 4 xx2000000409 A Mechanical stop, axis 4, flange B Mechanical stop, axis 4, slider Continues on next page Product manual - IRB 1300 87 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.4.2 Mechanically restricting the working range Continued Axis 5 xx2000002181 Installation of mechanical stops 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 and replace the stops, see: • Replacing the axis-1 mechanical stops on page 290 • Replacing the axis-2 mechanical stops on page 292 • Replacing the axis-3 mechanical stops on page 486 • Replacing the axis-4 mechanical stops on page 489 88 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.5.1 Additional installation procedure, Clean Room 3.5 Making robot ready for operation 3.5.1 Additional installation procedure, Clean Room General Robots with protection type Clean Room are specially designed to work in a clean room environment. Clean Room robots are designed to prevent from particle emission from the robot. For example, the maintenance work possible to perform without cracking the paint. The robot is painted with four layers of polyurethane paint. The last layer being a varnish over labels to simplify cleaning. The paint has been tested regarding outgassing of Volatile Organic Compounds (VOC) and been classified in accordance with ISO 14644-8. Any Clean Room parts that are replaced must be replaced with parts designed for use in Clean Room environments. Clean Room class 4 According to IPA test result, the robot IRB 1300 is suitable for use in Clean Room environment. Classification of airborne molecular contamination Parameter Outgassing amount Area (m 2 ) Test duration (s) Temp (°C) Performed test Total detec- Norm based Classificaon 1m 2 and tion in acted (ng) cordance to 1s(g) ISO 146448 4.5E-03 3600 23 TVOC 2848 1.7E-07 -6.8 4.5E-03 60 90 TVOC 46524 1.7E-04 -3.8 Preparations before commissioning a Clean Room robot During transport and handling of a Clean Room robot, it is likely that the robot has been contaminated with particles of different kinds. Therefore the robot must be carefully cleaned before installation. Do not apply force on the plastic covers when lifting the robot! This may result in damage or cracks in the paint around the plastic cover. Product manual - IRB 1300 89 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.6.1 Robot cabling and connection points 3.6 Electrical connections 3.6.1 Robot cabling and connection points 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. DANGER Turn off the main power before connecting any cables. CAUTION Verify that the robot serial number is according to the number(s) in the Declaration of Incorporation (DoI). Main cable categories The following table specifies cabling categories between the robot and the controller. Some of the cabling belong to optional applications. Cable category Description Robot cables Handles power supply to and control of the robot's motors as well as feedback from the serial measurement board. Specified in the table Robot cables on page 90. Customer cables Handles communication with equipment fitted on the robot by the customer, low voltage signals and high voltage power supply + protective ground. The customer cables also handle databus communication. The customer cables also include the air hose. See the product manual for the controller, see document number in References on page 10. Air hoses The hose for compressed air is integrated with the manipulator cable harness. 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 point, cabinet Connection point, robot Robot cables, power Transfers drive power from the X1 drive units in the control cabinet to the robot motors. R1.MP Robot cable, signals Transfers resolver data from X2 and power supply to the serial measurement board. R1.SMB Continues on next page 90 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.6.1 Robot cabling and connection points Continued Robot cable, power Power cable length Article number Power cable 3 m 3HAC061139-001 Power cable 7 m 3HAC061139-002 Power cable 15 m 3HAC061139-003 Signal cable length Article number Signal cable, shielded: 3 m 3HAC067446-001 Signal cable, shielded: 7 m 3HAC067446-002 Signal cable, shielded: 15 m 3HAC067446-003 Robot cable, signals Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. A B xx1600002016 A Diameter B Diameter x10 Continues on next page Product manual - IRB 1300 91 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.6.1 Robot cabling and connection points Continued Grounding and bonding point on manipulator There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx2000000414 Installation of extra O-rings For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Continues on next page 92 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.6.1 Robot cabling and connection points Continued An extra O-ring is delivered together with the robot and must be fitted to the robot during installation. Equipment Article number Note O-ring 3HAB3772-19 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used to seal between the main power cable and connector. Robots with manipulator cables routed from the rear of the base: xx2000002338 Robots with manipulator cables routed from below (3309-1): xx2000002339 Customer cables - CP/CS cable CP/CS cable length Article number i 3m 3HAC067449-001 7m 3HAC067449-002 15 m 3HAC067449-003 i It is recommended to always use the CP/CS cable provided by ABB. If users still require to do wiring by their own, make sure to use R1.C1 connector in M12 A-code 12p female type. It is the responsibility of the users to guarantee the safety of the system when self-prepared cables and connectors are used. Customer cables - Ethernet floor cable Ethernet floor cable length Article number i 7m 3HAC067447-002 15 m 3HAC067447-003 i It is recommended to always use the Ethernet floor cable provided by ABB. If users still require to do wiring by their own, make sure to use R1.C2 connector in M12 X-code male type. It is the responsibility of the users to guarantee the safety of the system when self-prepared cables and connectors are used. Product manual - IRB 1300 93 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.6.2 Customer connections 3.6.2 Customer connections Introduction to customer connections The cables for customer connection are integrated in the robot and the connectors are placed on the tubular and one at the base. There are two connectors R2.C1 and R2.C3 at the tubular. Corresponding connectors R1.C1 and R1.C3 are located at the base. There is also connections for Ethernet, one connector R2.C2 at the tubular and the corresponding connector R1.C2 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. (D) (A) (B) (C) (B) (A) (A) (B) (C) (D) xx2000001007 Position Connection Description A (R1)R2.C1 Customer power/signal 12 wires 30 V, 1.5 A B (R1)R2.C2 Customer power/signal 8 wires or Ethernet 30 V, 1 A or 1 Gbits/s C (R1)R2.C3 Customer power/signal 4 wires 42 V DC or 25 V AC, 4 A i D Air Max. 6 bar Outer diameter of air hose: 6 mm i Number 4 Value Contact ABB for more information if to use the (R1)R2.C3 connection for an application with a higher voltage. Continues on next page 94 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.6.2 Customer connections Continued Connector kits (optional) Connector kits, base R1.C1 and R1.C2 connectors on the base are parts of the CP/CS cable and Ethernet floor cable, respectively. For details about the robot cabling, see Robot cabling and connection points on page 90. Customers need to do wiring when using the R1.C3 connector on the base. Make sure to use the R1.C3 connector in M12 A-code 4p female type. Connector kits, tubular The table describes the CP/CS and Ethernet (if any) connector kits for tubular. Position Description Connector kits CP/CS Art. no. R2.C1 M12 CPCS Male straight connector kits 3HAC066098-001 M12 CPCS Male angled con- 3HAC066099-001 nector kits R2.C3 M12 CPCS Male straight connector kits 3HAC068412-001 M12 CPCS Male angled con- 3HAC068413-001 nector kits Ethernet R2.C2 M12 Ethernet CAT6a Male straight connector kits 3HAC067413-001 M12 Ethernet CAT6a Male angled connector kits 3HAC067414-001 Continues on next page Product manual - IRB 1300 95 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.6.2 Customer connections Continued Protection covers Protection covers for water and dust proofing Protection covers are delivered together with the robot and must be well fitted to the connectors in any application requiring water and dust proofing. Always remember to refit the protection covers after removing them. (C) (A) (B) (A) (C) xx2000001008 A CP/CS or Ethernet connector protection covers B SMB connector protection cover C Air hose connector protection covers 96 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.7 Start of robot in cold environments 3.7 Start of robot in cold environments Introduction This section describes how to start the robot in a cold environment if it is not starting the normal way. Problems with starting the robot Event message from Motion Supervision Use this procedure if an event message indicates a problem with Motion supervision at start-up. More information about Motion Supervision is found in Technical reference manual - System parameters. Action Note 1 Turn off Motion Supervision. 2 Start the robot. 3 When the robot has reached normal working temperature, the Motion Supervision can be turned on again. Robot stopping with other event message Use this procedure if the robot is not starting. 1 Action Note Start the robot with its normal program but with reduced speed. The speed can be regulated with the RAPID instruction VelSet or the speed regulator on the FlexPendent. Note It is recommended to reduce the speed to a value smaller than 30% of the normal programmed speed. 2 After 10 minutes or more, run the robot with The warm up duration varies according the normal speed again. to the working cycle. If the working cycle is not tough enough, a longer warm up duration is required. Adjusting the speed and acceleration during warm-up Depending on how cold the environment is and what program is being used, the speed might need to be ramped up until reached maximum. The table shows examples of how to adjust the speed: Work cycles AccSet Speed/velocity 3 Work cycles 20, 20 v100 (100 mm/s) 5 Work cycles 40, 40 v400 (400 mm/s) 5 Work cycles 60, 60 v600 (600 mm/s) 5 Work cycles 100, 100 v1000 (1000 mm/s) More than 5 Work cycles 100, 100 Max. Continues on next page Product manual - IRB 1300 97 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.7 Start of robot in cold environments Continued 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. 98 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 3 Installation and commissioning 3.8 Test run after installation, maintenance, or repair 3.8 Test run after installation, maintenance, or repair Safe handling Use the following procedure after installation, maintenance, or repair, before initiating motion. DANGER Initiating motion without fulfilling the following aspects, may increase the risk for injury or cause 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 Verify that all safety equipment is installed, as designed for the application. 6 Verify that no personnel are inside the safeguarded space. 7 If maintenance or repair has been done, verify the function of the part that was maintained. 8 Verify the application in the operating mode manual reduced speed. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before initiating motion. Product manual - IRB 1300 99 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. This page is intentionally left blank 4 Maintenance 4.1 Introduction 4 Maintenance 4.1 Introduction Structure of this chapter This chapter describes all the maintenance activities recommended for the IRB 1300. It is based on the maintenance schedule found at the beginning of the chapter. The schedule contains information about required maintenance activities including intervals, and refers to procedures for the activities. Each procedure contains all the information required to perform the activity, including required tools and materials. The procedures are gathered in different sections and divided according to the maintenance activity. Safety information Observe all safety information before conducting any service work. There are general safety aspects that must be read through, as well as more specific safety information that describes the danger and safety risks when performing the procedures. Read the chapter Safety on page 15 before performing any service work. The maintenance must be done by qualified personnel in accordance with the safety requirements set forth in the applicable national and regional standards and regulations. Note If the IRB 1300 is connected to power, always make sure that the IRB 1300 is connected to protective earth and a residual current device (RCD) before starting any maintenance work. For more information see: • Product manual - OmniCore C30 • Product manual - OmniCore C90XT • Product manual - OmniCore E10 • Robot cabling and connection points on page 90. Product manual - IRB 1300 101 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.2.1 Specification of maintenance intervals 4.2 Maintenance schedule and expected component life 4.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 1300: • 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. • SIS: specified by the robot's SIS (Service Information System). A typical value is given for a typical work cycle, but the value will differ depending on how hard each part is run. The SIS used in OmniCore is further described in the Operating manual - OmniCore. Robots with the functionality Service Information System activated can show active counters in the device browser in RobotStudio, or on the FlexPendant. 102 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.2.2 Maintenance schedule 4.2.2 Maintenance schedule Scheduled and non-predictable maintenance The robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately! Life of each component The inspection intervals do not specify the life of each component. Values for these are specified in the section Expected component life on page 105 Every 30,000 hours ii Every 24,000 hours ii Every 12,000 hours ii Every 36 months Maintenance activities Regularly i Every 12 months Maintenance schedule Cleaning the robot x Cleaning the IRB 1300 on page 106 x Check for abnormal wear or contamination. For robots with protection type Clean Room: Inspect daily x Inspect the oil level in the actual gearbox if there is a suspected leakage, after an oil change or a maintenance or repair activity where draining and filling oil is required. Inspecting the robot Inspecting the oil level in gearboxes Reference Inspecting the information labels x Inspecting the information labels on page 108 Inspecting the robot harness x iii Inspecting the robot cabling on page 110 Inspecting the mechanical stop x Inspecting mechanical stops on page 111 Inspecting the timing belt x Lubricating the cable package on page 119 x iv Lubricating the robot harness Replacing the SMB battery pack Inspecting timing belts on page 115 xv Replacing the battery pack on page 122 Continues on next page Product manual - IRB 1300 103 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance Changing the oil in axis-1 gearbox Changing the oil in axis-2 gearbox Running the Brake Check routine vi Running the Cyclic Brake Check routine vi Every 30,000 hours ii Every 24,000 hours ii Every 12,000 hours ii Every 36 months Maintenance activities Every 12 months Regularly i 4.2.2 Maintenance schedule Continued Reference x First change when DTC ii reads: • 6000 hours Second change when DTC ii reads: • 24000 hours Following changes: • 24000 hours Changing oil, axis-1 gearbox on page 130 x First change when DTC ii reads: • 6000 hours Second change when DTC ii reads: • 24000 hours Following changes: • 24000 hours Changing oil, axis-2 gearbox on page 135 x vii Recommended to robots without the SafeMove option. See Operating manual - OmniCore. x vii Recommended to robots with the SafeMove option. See Application manual - Functional safety and SafeMove. Overhaul of complete robot x 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 Operating hours counted by the DTC = Duty time counter. iii Replace when damage or cracks is detected or life limit is approaching. iv Replace when damage or cracks is detected or life limit is approaching. v The battery is to be replaced at given maintenance interval or at battery low alert. vi Not needed separately if already included in the application. vii Recommended test interval is within the range 8-48 hours. 104 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.2.3 Expected component life 4.2.3 Expected component life Expected life depends on usage The expected life of a specific component of the robot can vary greatly depending on how hard it is run. Expected component life Component Expected life Cable harness, normal usage i 40000 hours ii Note Cable harness, extreme us- 20000 hours ii age iii Gearboxes i ii iii 30000 hours Examples of "normal usage" in regard to movement: most material handling applications and limited use of bending backwards mode of axis 3. Severe chemical or thermal environments, or similar environments, can result in shortened life expectancy. Examples of "extreme usage" in regard to movement: press tending, very severe palletizing applications, major use of axis 1 movement and major use of bending backwards of axis 3. Product manual - IRB 1300 105 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.3.1 Cleaning the IRB 1300 4.3 Cleaning activities 4.3.1 Cleaning the IRB 1300 General To secure high uptime it is important that the IRB 1300 is cleaned regularly. The frequency of cleaning depends on the environment in which the manipulator works. Different cleaning methods are allowed depending on the type of protection of the IRB 1300. Note Always verify the protection type of the robot before cleaning. WARNING Turn off all electrical power supplies to the robot before starting the cleaning. Special cleaning considerations This section specifies some special considerations when cleaning the robot. • Always use cleaning equipment as specified. Any other cleaning equipment may shorten the life of the robot. • Always check that all protective covers are fitted to the robot before cleaning. • Do not point the water jet at connectors, joints, sealings or gaskets. • Do not use compressed air to clean the robot. • Do not use solvents that are not approved by ABB to clean the robot. • Do not spray from a distance closer than 0.4 m. • Do not remove any covers or other protective devices before cleaning the robot. Cleaning methods This following table defines what cleaning methods are allowed for ABB manipulators depending on the protection type. Protection type Standard IP40 Cleaning method Vacuum cleaner Wipe with cloth Rinse with water High pressure water or steam Yes Yes. With light No cleaning detergent. No IP67 (option) Yes Yes. With light Yes. It is highly re- No cleaning deter- commended that gent. the water contains a rust-prevention solution and that the manipulator is dried afterwards. Continues on next page 106 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.3.1 Cleaning the IRB 1300 Continued Protection type Cleaning method Vacuum cleaner Wipe with cloth Rinse with water High pressure water or steam Foundry Plus Yes Yes. With light Yes. It is highly re- No cleaning deter- commended that gent or spirit. the water contains a rust-prevention solution. Clean room Yes. With light No cleaning detergent, spirit or isopropyl alcohol. Yes No Cleaning with water and steam Instructions for rinsing with water IRB 1300 with protection class IP67 (option) and with protection type Foundry Plus can be cleaned by rinsing with water (water cleaner). 1 The following list defines the prerequisites: I • Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I • Fan jet nozzle should be used, min. 45° spread • Minimum distance from nozzle to encapsulation: 0.4 meters • Maximum flow: 20 liters/min I Typical tap water pressure and flow Cables Movable cables need to be able to move freely: 1 • 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. See Cleaning methods on page 106 for exceptions. Product manual - IRB 1300 107 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.4.1 Inspecting the information labels 4.4 Inspection activities 4.4.1 Inspecting the information labels Location of labels These figures show the location of the information labels to be inspected. The symbols are described in section Safety symbols on manipulator labels on page 19. A A FOUNDRY PLUS Clean Room 2 A J H C B D F UL WEEE Calibration label E G xx2000000500 A ABB logo B Read manual label, also specifying warning labels C Instruction label Brake release D WEEE label E Rating label, CE label and AbsAcc label F UL label G Calibration label H Foundry Plus label J Clean Room label Required tools and equipment Visual inspection, no tools are required. Continues on next page 108 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.4.1 Inspecting the information labels Continued Inspecting, labels Action Note 1 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 2 Inspect the labels, located as shown in the figures. 3 Replace any missing or damaged labels. Product manual - IRB 1300 109 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.4.2 Inspecting the robot cabling 4.4.2 Inspecting the robot cabling Introduction CAUTION For robots with protection type Clean Room Always read the specific instructions before doing any repair work, see Cut the paint or surface on the robot before replacing parts on page 145 Location of robot cabling The robot cabling comprises the cabling between the robot and controller cabinet. Required tools and equipment Visual inspection, no tools are required. Other tools and procedures may be required if the spare part needs to be replaced. These are specified in the replacement procedure. Inspection, robot cabling Use this procedure to inspect the robot cabling. Action Note 1 DANGER Turn off all: • electric power supply to the robot • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. 2 Visually inspect: • the control cabling between the robot and control cabinet Look for abrasions, cuts or crush damage. 3 Replace the cabling if wear or damage is detected. 110 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.4.3 Inspecting mechanical stops 4.4.3 Inspecting mechanical stops 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 145 Location of mechanical stops Axis 1 xx2000000406 A Mechanical stop, axis 1, slider B Mechanical stop, axis 1, fixed block Continues on next page Product manual - IRB 1300 111 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.4.3 Inspecting mechanical stops Continued Axis 2 xx2000000407 Axis 3 IRB 1300-11/0.9, IRB 1300-7/1.4 and IRB 1300-12/1.4 IRB 1300-10/1.15 xx2000000408 xx2000000471 Continues on next page 112 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.4.3 Inspecting mechanical stops Continued Axis 4 xx2000000409 A Mechanical stop, axis 4, flange B Mechanical stop, axis 4, slider Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Mechanical stop, axis 1, fixed block 3HAC064478-001 Replace if damaged. Mechanical stop, axis 1, slider 3HAC065755-001 Replace if damaged. Mechanical stop, block A 3HAC065651-001 Replace if damaged. Mechanical stop, block B 3HAC065671-001 Used for axis 3 of IRB 130010/1.15. Replace if damaged. Mechanical stop, axis 4, flange 3HAC065805-001 Replace if damaged. Mechanical stop, axis 4, slider 3HAC065804-001 Replace if damaged. Continues on next page Product manual - IRB 1300 113 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.4.3 Inspecting mechanical stops Continued Required tools and equipment Note The axis-1 mechanical stops are accessible after removing the base, see Replacing the base on page 208. The axis-4 mechanical stops are accessible after removing the housing, see Replacing the housing and extender unit on page 359. Visual inspection, no tools are required. Other tools and procedures may be required if the spare part needs to be replaced. These are specified in the replacement procedure. Inspecting mechanical stops Use this procedure to inspect mechanical stops on axes 2 and 3. Action Information 1 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Inspect the mechanical stops. 4 Replace if the mechanical stop is: • bent • loose • damaged. See figures in Location of mechanical stops on page 111. Note The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop. 114 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.4.4 Inspecting timing belts 4.4.4 Inspecting timing belts Introduction CAUTION Always read the section "General procedures" before doing any repair work. Cut the paint or surface on the robot before replacing parts on page 145. Location of timing belts Note It is recommended to inspect the axis-4 timing belt when replacing the motor. Continues on next page Product manual - IRB 1300 115 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.4.4 Inspecting timing belts Continued The timing belts are located as shown in the figures. Axis Location 3 xx2000001490 4 xx2000001491 5 Continues on next page 116 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.4.4 Inspecting timing belts Continued Axis Location xx2000001492 6 xx2000001493 Required tools and equipment Equipment Note Standard toolkit The content is defined in the section Standard toolkit on page 759. Other tools and procedures may be required if the spare part needs to be replaced. These are specified in the replacement procedure. Timing belt tension The table describes the timing belt tension. Axis Force Frequency Used timing belt i New timing belt Used timing belt i New timing belt Axis 3 30.2-34.5 N 43.1-47.4 N 73.4-78.5 Hz 87.8-92.1 Hz Axis 4 16.7-19.1 N 23.9-26.2 N 175-187 Hz 209-219 Hz Axis 5 9.68-11.1 N 13.8-15.2 N 59.3-63.4 Hz 70.8-74.3 Hz Continues on next page Product manual - IRB 1300 117 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.4.4 Inspecting timing belts Continued Axis Axis 6 i Force Frequency Used timing belt i New timing belt Used timing belt i New timing belt 8.79-10.0 N 12.6-13.8 N 85.7-91.6 Hz 102-107 Hz Used belt is the one having been installed and used for more than 12 hours. Compared with the new timing belt, the force value decreases 15% and the frequency value decreases 28% when the timing belt has been installed and used for more than 12 hours but less than 150 hours. When the timing belt has been installed and used for more than 150 hours, both the force and frequency values decrease 30%. Inspecting timing belts Use this procedure to inspect timing belts. Action Information 1 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 Gain access to each timing belt by removing the cover. 3 Check the timing belts for damage or wear. 4 Check the timing belt pulleys for damage. 5 If any damage or wear is detected, the part must be replaced! 6 Use a sonic tension meter to measure the See Timing belt tension on page 117. timing belt tension. If the belt has no tension, adjust it! 118 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.5.1 Lubricating the cable package 4.5 Lubrication activities 4.5.1 Lubricating the cable package Location of the cable package The IRB 1300 main cable package has three lengths corresponding to three robot variants, and is also differentiated by connector interface location. The cable packages are located as shown in the figures. Robot type Rear connector interface Bottom connector interface IRB 130011/0.9 xx2000001260 xx2000001261 IRB 130010/1.15 xx2000001258 xx2000001259 Continues on next page Product manual - IRB 1300 119 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.5.1 Lubricating the cable package Continued Robot type Rear connector interface Bottom connector interface IRB 13007/1.4 and IRB 1300-12/1.4 xx2000001256 xx2000001257 Required tools and equipment Equipment Note Standard toolkit The content is defined in the section Standard toolkit on page 759. Other tools and procedures may be required if the spare part needs to be replaced. These are specified in the replacement procedure. Required consumables Consumable Article number Note Grease 3HAC029132-001 FM 222 Lubricating the cable package Use this procedure to lubricate the cable package. Action Information 1 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 Gain access to the cable package by removing the covers. Continues on next page 120 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.5.1 Lubricating the cable package Continued Action Information 3 Check the cable package for damage or wear. 4 If any damage or wear is detected, the part See Replacing the cable package on must be replaced! page 148. 5 Apply grease to the cable package, cover all moving area of the package. 6 Apply grease to the covers that have contacting area with the cable package. Product manual - IRB 1300 121 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.6.1 Replacing the battery pack 4.6 Replacement activities 4.6.1 Replacing the battery pack Location of the battery pack The battery pack is located as shown in the figure. xx2000001495 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Battery pack 3HAC044075-001 Battery includes protection circuits. Only replace with the specified spare part or an ABB-approved equivalent. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Continues on next page 122 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.6.1 Replacing the battery pack Continued Equipment Article number Note Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Consumable Article number Note Cable straps - Grease 3HAC029132-001 Required consumables FM 222 Removing the battery pack Use these procedures to remove the battery pack. Preparations before removing the battery pack Action Note 1 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 123 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.6.1 Replacing the battery pack Continued Disconnecting the SMB connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 3 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 4 Remove the SMB cover attachment screws and carefully open the cover. CAUTION Clean cover from metal residues before opening. Metal residues can cause shortage on the boards which can result in hazardous failures. CAUTION xx2000001503 There are cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. 5 Disconnect the connectors. • SMB.J1 • SMB.J2 • R2.SMB Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. 6 xx2000001504 Remove the SMB cover completely from the base. Continues on next page 124 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.6.1 Replacing the battery pack Continued Removing the battery pack Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 3 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 125 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.6.1 Replacing the battery pack Continued Action 4 Note Disconnect the battery cable. xx2000001505 5 Remove the battery pack by cutting the cable strap. xx2000001506 Refitting the battery pack Use these procedures to refit the battery pack. Refitting the battery pack Action Note 1 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 2 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 126 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.6.1 Replacing the battery pack Continued Action 3 Note Secure the battery pack using the cable strap. xx2000001506 4 Reconnect the battery cable. xx2000001505 Reconnecting the SMB connectors Action Note 1 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 2 For robots with protection type Clean Room Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for SMB cover: 3HAC067820-001 xx2000002508 Continues on next page Product manual - IRB 1300 127 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.6.1 Replacing the battery pack Continued 4 Action Note Reconnect the connectors. • SMB.J1 • SMB.J2 • R2.SMB Tightening torque: 0.3 Nm Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001504 5 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 6 Refit the SMB cover to the base. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 2.6 Nm xx2000001503 Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. 3 DANGER Make sure all safety requirements are met when performing the first test run. 128 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.1 Type of lubrication in gearboxes 4.7 Changing activities 4.7.1 Type of lubrication in gearboxes Introduction This section describes where to find information about the type of lubrication, article number and the amount of lubrication in the specific gearbox. It also describes the equipment needed when working with lubrication. Type and amount of oil in gearboxes Information about the type of lubrication, article number as well as the amount in the specific gearbox can be found in Technical reference manual - Lubrication in gearboxes available for registered users on myABB Business Portal, www.abb.com/myABB. Location of gearboxes The figure shows the location of the gearboxes. xx2000001510 A Gearbox, axis 1 (inside base) B Gearbox, axis 2 C Gearbox, axis 3 D Gearbox, axis 4 (inside housing) Product manual - IRB 1300 129 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.2 Changing oil, axis-1 gearbox 4.7.2 Changing oil, axis-1 gearbox Location of oil plugs The oil plugs of the gearbox are located as shown in the figure. xx2000001511 A Oil plug, filling and venting B Quick coupling, draining Required tools and equipment Equipment, etc. Article number Note Oil collecting vessel - The capacity of the vessel must be sufficient to take the complete amount of oil. Connector for quick coupling, with outlet pipe Used for draining and filling oil to axis1 gearbox. Connector specification: G3/8 Oil dispenser - Includes pump with outlet pipe. Standard toolkit - Content is defined in section Standard toolkit on page 759. Consumable Material Note Lubricating oil Information about the oil is found in Technical reference manual - Lubrication in gearboxes. See Type and amount of oil in gearboxes on page 129. Continues on next page 130 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.2 Changing oil, axis-1 gearbox Continued Required documents Document name Document number Technical reference manual - Lubrication in gearboxes 3HAC042927-001 Draining the axis-1 gearbox Use this procedure to drain the gearbox. Preparations before draining oil Action 1 Note Jog all axes to zero position. xx2000001520 2 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 3 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Draining oil of axis-1 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. Continues on next page Product manual - IRB 1300 131 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.2 Changing oil, axis-1 gearbox Continued Action Note 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. 3 Place the oil collecting vessel underneath the quick coupling. xx2000001514 4 Remove the oil plugs and keep them opened to speed up the drainage. xx2000001513 5 Plug a G3/8 quick coupling connector with pipe to the quick coupling on base. 6 WARNING Used oil is hazardous material and must be disposed of in a safe way. See Decommissioning on page 747 for more information. 7 Drain the gearbox oil. Note Draining is time-consuming. Elapsed time varies depending on the temperature of the oil. 8 Remove the quick coupling connector and clean the pipe after the oil is drained. Note There will be some oil left in the gearbox after draining. Continues on next page 132 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.2 Changing oil, axis-1 gearbox Continued 9 Action Note Refit oil plugs. Tightening torque: 10 Nm Filling oil into the axis-1 gearbox Use this procedure to refill the gearbox with oil. Refilling oil to axis-1 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. 3 Open the oil plugs, one for filling and the other for venting. xx2000001513 4 WARNING Overfilling of gearbox lubricant can lead to internal over-pressure inside the gearbox which in turn may: • damage seals and gaskets • completely press out seals and gaskets • prevent the robot from moving freely. 5 Refill the gearbox with oil. Note Type of oil and total amount is detailed in Technical reference manual - Lubrication in gearboxes. The amount of oil to be filled depends on the amount previously being drained. 6 Refit the oil plugs. Tightening torque: 10 Nm Continues on next page Product manual - IRB 1300 133 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.2 Changing oil, axis-1 gearbox Continued Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 DANGER Make sure all safety requirements are met when performing the first test run. 134 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.3 Changing oil, axis-2 gearbox 4.7.3 Changing oil, axis-2 gearbox Location of oil plugs The oil plugs of the gearbox are located as shown in the figure. xx2000001512 A Oil plug, filling and venting B Oil plug, filling, draining and venting Required tools and equipment Equipment, etc. Article number Note Oil collecting vessel - The capacity of the vessel must be sufficient to take the complete amount of oil. Oil dispenser - Includes pump with outlet pipe. Standard toolkit - Content is defined in section Standard toolkit on page 759. Consumable Material Note Lubricating oil Information about the oil is found in Technical reference manual - Lubrication in gearboxes. See Type and amount of oil in gearboxes on page 129. Continues on next page Product manual - IRB 1300 135 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.3 Changing oil, axis-2 gearbox Continued Required documents Document name Document number Technical reference manual - Lubrication in gearboxes 3HAC042927-001 Draining the axis-2 gearbox Use this procedure to drain the gearbox. Preparations before draining oil Action Note 1 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 Jog the robot to the specified position: • Axis 1: 0° • Axis 2: -67.5 • Axis 3: 0° • Axis 4: 0° • Axis 5: 0° • Axis 6: No significance. xx2000001519 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 136 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.3 Changing oil, axis-2 gearbox Continued Draining oil of axis-2 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. 3 Place the oil collecting vessel underneath the oil plug, draining. xx2000001515 4 Remove the oil plug, draining. xx2000001516 5 Plug a clean pipe to the oil plug, draining, with the other end to the oil collecting vessel. 6 Remove the oil plug, venting and keep it opened to speed up the drainage. xx2000001517 Continues on next page Product manual - IRB 1300 137 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.3 Changing oil, axis-2 gearbox Continued Action Note 7 WARNING Used oil is hazardous material and must be disposed of in a safe way. See Decommissioning on page 747 for more information. 8 Drain the gearbox oil. Note Draining is time-consuming. Elapsed time varies depending on the temperature of the oil. 9 Remove and clean the pipe after the oil is drained. Note There will be some oil left in the gearbox after draining. 10 Refit oil plugs. Tightening torque: 10 Nm Filling oil into the axis-2 gearbox Use this procedure to refill the gearbox with oil. Refilling oil to axis-2 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. Continues on next page 138 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.3 Changing oil, axis-2 gearbox Continued Action 3 Note Open the upper oil plug. Note The lower oil plug has to be closed; otherwise, the oil may leak before required oil amount is filled. xx2000001518 A Oil plug, opened B Oil plug, closed 4 WARNING Overfilling of gearbox lubricant can lead to internal over-pressure inside the gearbox which in turn may: • damage seals and gaskets • completely press out seals and gaskets • prevent the robot from moving freely. 5 Refill the gearbox with oil. Note Type of oil and total amount is detailed in Technical reference manual - Lubrication in gearboxes. The amount of oil to be filled depends on the amount previously being drained. CAUTION Oil filling must be slow to make sure air venting is fluent. 6 Inspect the oil level by measuring the level at the upper oil plug hole. Required oil level: within the range of 64 mm to 69 mm below the edge of the oil plug hole. CAUTION The oil level sinks when the oil fills all cavities in the gearbox. Wait until the oil stops sinking, before measuring the oil level. xx2000001580 7 Refit the oil plug. Tightening torque: 10 Nm Continues on next page Product manual - IRB 1300 139 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 4 Maintenance 4.7.3 Changing oil, axis-2 gearbox Continued Action Note 8 DANGER Make sure all safety requirements are met when performing the first test run. Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 DANGER Make sure all safety requirements are met when performing the first test run. 140 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.1 Introduction 5 Repair 5.1 Introduction Structure of this chapter This chapter describes repair activities for the IRB 1300. Each procedure contains the information required to perform the activity, for example spare parts numbers, required special tools, and materials. WARNING Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 1300, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit. This is particularly important for safety equipment to maintain the safety integrity of the installation. Safety information Make sure to read through the chapter Safety on page 15 before commencing any service work. Note The robot should be secured with the transportation brackets during removing from/refitting to the foundation. Note If the IRB 1300 is connected to power, always make sure that the IRB 1300 is connected to protective earth and a residual current device (RCD) before starting any repair work. For more information see: • Product manual - OmniCore C30 • Product manual - OmniCore C90XT • Product manual - OmniCore E10 Product manual - IRB 1300 141 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.2.1 Mounting instructions for sealings 5.2 General procedures 5.2.1 Mounting instructions for sealings General This section describes how to mount different types of sealings. Equipment Consumable Article number Note Grease 3HAC042536-001 Shell Gadus S2 Rotating sealings The procedure below describes how to fit rotating sealings. CAUTION Please observe the following before commencing any assembly of sealings: • Protect the sealing during transport and mounting, especially the main lip. • Keep the sealing in its original wrappings or protect it well before actual mounting. • The fitting of sealings and gears must be carried out on clean workbenches. • Use a protective sleeve for the main lip during mounting, when sliding over threads, keyways or other sharp edges. Action Note 1 Check the sealing to ensure that: • The sealing is of the correct type. • There is no damage on the main lip. 2 Inspect the shaft surface before mounting. If scratches or damage are found, the shaft must be replaced since it may result in future leakage. Do not try to grind or polish the shaft surface to get rid of the defect. Continues on next page 142 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.2.1 Mounting instructions for sealings Continued Action 3 Note Lubricate the sealing with grease just before fitting. Article number is specified in (Not too early - there is a risk of dirt and foreign Equipment on page 142. particles adhering to the sealing.) Fill 2/3 of the space between the dust lip and the main lip with grease. If the sealing is without dust lip, just lubricate the main lip with a thin layer of grease. B A C xx2000000071 A Main lip B Grease C Dust lip 4 Mount the sealing correctly with a mounting tool. Never hammer directly on the sealing as this may result in leakage. A xx2000000072 A Gap 5 Make sure that no grease is left on the robot surface. Continues on next page Product manual - IRB 1300 143 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.2.1 Mounting instructions for sealings Continued Flange sealings and static sealings The following procedure describes how to fit flange sealings and static sealings. Action 1 Check the flange surfaces. They must be even and free from pores. It is easy to check flatness using a gauge on the fastened joint (without sealing compound). If the flange surfaces are defective, the parts may not be used because leakage could occur. 2 Clean the surfaces properly in accordance with the recommendations of ABB. 3 Distribute the sealing compound evenly over the surface, preferably with a brush. 4 Tighten the screws evenly when fastening the flange joint. O-rings The following procedure describes how to fit o-rings. Action Note 1 Ensure that the correct o-ring size is used. 2 Check the o-ring for surface defects, burrs, shape accuracy, or deformation. 3 Check the o-ring grooves. 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 Check that the o-ring is not squashed outside the o-ring groove. 7 Make sure that no grease is left on the robot surface. Defective o-rings, including damaged or deformed o-rings, may not be used. 144 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.2.2 Cut the paint or surface on the robot before replacing parts 5.2.2 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. For robots with protection type Clean Room When replacing parts on the robot, it is important to make sure that after the replacement, no particles will be emitted from the joint between the structure and the new part, and that the easy cleaned surface is retained. Required equipment Equipment Spare parts Note Sealing compound 3HAC026759-001 Sikaflex 521 FC. Color white. Tooling pin Width 6-9 mm, made of wood. Cleaning agent Ethanol Knife Lint free cloth Touch up paint Clean Room/Hy- 3HAC036639-001 gienic White Touch up paint Standard/Foundry 3HAC067974-001 Plus Graphite White Removing Action 1 Description Cut the paint with a knife in the joint between the part that will be removed and the structure, to avoid that the paint cracks. xx0900000121 2 Carefully grind the paint edge that is left on the structure to a smooth surface. Refitting 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. Continues on next page Product manual - IRB 1300 145 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.2.2 Cut the paint or surface on the robot before replacing parts Continued Action 3 Description Seal all refitted joints with sealing compound. xx0900000122 4 Use the tooling pin to even out the surface of the sealing compound. xx0900000125 5 For robots with protection type Clean Room For robots with protection type Clean Room Wait 10 minutes. Sikaflex 521FC skin dry time (10 minutes). 6 Use Touch up paint Clean Room/Hygienic, white to paint any damaged surfaces. 3HAC036639-001 Note Always read the instruction in the product data sheet in the paint repair kit for Clean Room/Hygienic. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. 146 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.2.3 The brake release buttons may be jammed after service work 5.2.3 The brake release buttons may be jammed after service work Description The brake release unit has push-buttons for the brake release of each axis motor. When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting. DANGER If the power is turned on while a brake release button is jammed in depressed position, the affected motor brake is released. This may cause serious personal injuries and damage to the robot. Elimination To eliminate the danger after service work has been performed inside the SMB recess, follow the procedure below. Action 1 Make sure the power is turned off. 2 Remove the push-button guard, if necessary. 3 Verify that the push-buttons of the brake release unit are working by pressing them down, one by one. Make sure none of the buttons are jammed in the tube. 4 If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 1300 147 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package 5.3 Cable harness 5.3.1 Replacing the cable package Location of the cable package The main cable package runs from the base, up through the swing, lower arm and housing, and into the extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4) and tubular. The main cable package includes the air hoses and the cabling for all the six motors. Optional Ethernet cabling can also be included. The air hoses and optional Ethernet must be disconnected inside the tubular before the cable package can be removed. As standard feature, the connector interface is located at the rear of the base. The interface can also be bottom mounted, as an option. This section describes both configurations. The cable packages are located as shown in the figures. Robot type Rear connector interface Bottom connector interface IRB 130011/0.9 xx2000001260 xx2000001261 Continues on next page 148 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Robot type Rear connector interface Bottom connector interface xx2000001258 xx2000001259 IRB 130010/1.15 IRB 13007/1.4 and IRB 1300-12/1.4 xx2000001256 xx2000001257 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - IRB 1300 149 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Spare part Article number Note Main cable harness, S, basic 3HAC073303-001 Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, S (CP/CS and 3HAC073304-001 air hose, without Ethernet) Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, S (CP/CS and 3HAC073305-001 air hose, with Ethernet) Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, M, basic 3HAC073300-001 Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, M (CP/CS and 3HAC073301-001 air hose, without Ethernet) Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, M (CP/CS and 3HAC073302-001 air hose, with Ethernet) Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L, basic 3HAC073297-001 Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L (CP/CS and 3HAC073298-001 air hose, without Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L (CP/CS and 3HAC073299-001 air hose, with Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. 3HAC073306-001 Continues on next page 150 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Spare part Article number Note Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, S, basic, Clean Room 3HAC077833-001 Used with IRB 1300-11/0.9. Used with protection type Clean Room. Main cable harness, S, Clean 3HAC077834-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-11/0.9. Used with protection type Clean Room. Main cable harness, S, Clean Room (CP/CS and air hose, with Ethernet) 3HAC077835-001 Used with IRB 1300-11/0.9. Used with protection type Clean Room. Main cable harness, M, basic, Clean Room 3HAC077830-001 Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, M, Clean 3HAC077831-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, M, Clean Room (CP/CS and air hose, with Ethernet) 3HAC077832-001 Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, L, basic, Clean 3HAC077827-001 Room Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Main cable harness, L, Clean 3HAC077828-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Main cable harness, L, Clean Room (CP/CS and air hose, with Ethernet) 3HAC077829-001 Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Plastic cable protector, axis 2 3HAC067816-001 Plastic cable protector, axis 3 3HAC064693-001 Plastic cable protector, axis 4 3HAC064694-001 Continues on next page Product manual - IRB 1300 151 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Spare part Article number Note Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, short 3HAC073095-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, long 3HAC073096-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing top cover 3HAC073091-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Base cover 3HAC073090-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. SMB cover 3HAC076475-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Brake release unit 3HAC073296-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Swing cover, short, Clean Room 3HAC077824-001 Used with protection type Clean Room. Swing cover, long, Clean Room 3HAC077825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Continues on next page 152 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Spare part Article number Note Swing top cover, Clean Room 3HAC077820-001 Used with protection type Clean Room. Base cover, Clean Room 3HAC077819-001 Used with protection type Clean Room. SMB cover, Clean Room 3HAC077839-001 Used with protection type Clean Room. Brake release unit, Clean Room 3HAC077826-001 Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for SMB cover 3HAC067820-001 Not used with protection class IP40. Replace if damaged. Gasket for brake release unit 3HAC070274-001 Not used with protection class IP40. Replace if damaged. Gasket for base cover 3HAC067819-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Gasket for swing support, short 3HAC067822-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing support, long 3HAC067823-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, short 3HAC067824-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, long 3HAC067825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Continues on next page Product manual - IRB 1300 153 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Spare part Article number Note Gasket for swing top cover 3HAC067821-001 Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Consumable Article number Note Cable straps - Grease 3HAC029132-001 Required consumables FM 222 Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. Continues on next page 154 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action Note If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Removing the cable package Use these procedures to remove the cable package. Preparations before removing the cable package Action Note 1 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Removing the covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 155 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm support cover (C) • Swing support cover (D) • Swing top cover (E) xx2000001572 Loosening the cables in the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Cut the cable straps. xx2000001530 Continues on next page 156 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 4 Note Remove the connector plates. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001531 Disconnecting the axis-6 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP6 • FB6 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001532 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001533 Continues on next page Product manual - IRB 1300 157 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Disconnecting the axis-5 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP5 • FB5 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001534 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001535 Disconnecting CP/CS cabling (if equipped) Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 158 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 For robots with CP/CS cabling Disconnect the connectors. • J1.C1 • J1.C3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001536 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001537 Separating the cable package from the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 159 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 3 Note Remove the first semicircular bracket that fixes the cable package. xx2000001748 4 Remove the second semicircular bracket from the tubular. xx2000001749 Removing the process hub Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws and carefully open the cover. CAUTION There is cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. xx2000001538 Continues on next page 160 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 4 Note Disconnect the air hoses. xx2000001539 5 For robots with Ethernet cabling Access the connector from the process hub and disconnect the connector. • J1.C2 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001540 Tip The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Disconnecting the axis-4 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 161 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001542 4 Cut the cable strap. Note The motor cablings have another strap fixed. Always cut the strap that fixes the cable package to the plate. xx2000001543 5 Disconnect the connectors. • MP4 • FB4 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001544 6 Snap loose and remove the male head of the connectors from the connector plate. xx2000001545 Continues on next page 162 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Separating the cable package from the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the axis-4 cable protector. xx2000001546 Disconnecting the axis-2 and -3 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate, as shown in following step. xx2000001548 Continues on next page Product manual - IRB 1300 163 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 4 Note Cut the cable straps. xx2000001549 5 Disconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. 6 xx2000001550 Snap loose and remove the male head of the connectors from the connector plate. xx2000001551 Separating the cable package from the lower arm Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 164 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 3 Note Remove the cable bracket from the lower arm first and then from the cable package. xx2000001553 xx2100001465 4 Remove the connector plate. xx2000001554 Separating the cable package from the swing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 165 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 3 Note Remove the axis-2 cable protector. xx2000001556 4 Remove the cable brackets from the swing first and then from the cable package. xx2000001557 xx2100001466 Disconnecting the SMB connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. Continues on next page 166 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action Note 3 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 4 Remove the SMB cover attachment screws and carefully open the cover. CAUTION Clean cover from metal residues before opening. Metal residues can cause shortage on the boards which can result in hazardous failures. CAUTION xx2000001503 There are cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. 5 Disconnect the connectors. • SMB.J1 • SMB.J2 • R2.SMB Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. 6 xx2000001504 Remove the SMB cover completely from the base. Disconnecting the axis-1 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 167 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 3 Note Remove the connector plate from the base. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate, as shown in following step. xx2000001559 4 Disconnect the motor connectors. • FB1 • MP1 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001560 5 Snap loose and remove the male head of the connectors from the connector plate. xx2000001561 Opening the connector interface plate Notice that the procedure differs depending on if the connector interface is located either at the rear or at the bottom of the base. Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 168 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 3 Note Remove the connector interface plate attachment Valid for cabling with rear interscrews and carefully open the plate. face CAUTION There are cabling attached to the plate. The plate cannot be removed completely until the connectors are removed. xx2000001558 Valid for cabling with bottom interface (option 3309-1) xx2000001575 Disconnecting the earth cable Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Valid for cabling with bottom interface (option 3309-1) Remove the base rear cover. xx2000001573 Continues on next page Product manual - IRB 1300 169 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 4 Note Disconnect the earth cable. xx2000001574 Disconnecting the brake release connector Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 3 Cut the cable strap. 4 Disconnect the connector. • R2.BRU Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2100001480 Pulling out the cable package Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 170 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the axis-1 connector plate. xx2000001564 4 Wrap the connectors with the masking tape. 5 Pull out the cable package in the direction as shown in the figure. Note Slip out the cable protectors while pulling out the cable package. xx2000001563 6 Slip out the cable protectors. Refitting the cable package Use these procedures to refit the cable package. Securing the cable package in the base Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Wrap the connectors with the masking tape. Continues on next page Product manual - IRB 1300 171 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 3 Note Insert the cable package in the base and out from Valid for cabling with rear interthe SMB side. face CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001565 Valid for cabling with bottom interface (option 3309-1) xx2000001579 4 Insert the cable package up through the axis-1 gearbox and out from the swing top cover side. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001566 5 Refit the connector plate to the cable package. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001564 Continues on next page 172 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 6 Note Arrange the connectors as follows (facing the SMB side): • Right of the connector plate: - SMB.J1 - SMB.J2 - R2.MP1 on axis-1 motor - R2.FB1 on axis-1 motor • Left of the connector plate: - R2.SMB - R2.MP1 on main cable package - R2.FB1 on main cable package Reconnecting the axis-1 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001561 3 Reconnect the connectors. • FB1 • MP1 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001560 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Continues on next page Product manual - IRB 1300 173 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued 5 Action Note Refit the connector plate to the base. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001559 Securing the cable package in the swing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Route the cable package through the swing support. Make sure that: • the air hoses are facing the SMB side in the hollow tube of axis-1 gearbox. • the cable package is out from the hole near the base rear, as circled in the figure. CAUTION xx2000001745 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001747 Continues on next page 174 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued 3 Action Note Apply grease to the axis-2 cable protector and slip it over the cable harness. Grease: 3HAC029132-001 Plastic cable protector, axis 2: 3HAC067816-001 Note Note the correct direction of the cable protector. xx2000001567 4 Route the cable package up into the lower arm. Make sure that: • the air hoses are facing outside in the axis2 cable protector, see the figure as a guidance for the cable twisting way. • the axis-2 motor cablings are routed together with the main cable package up to the lower arm. CAUTION xx2000001746 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. 5 Refit the cable brackets to the cable package first Screw: M4x8 12.9 Lafre and then to the swing. 2C2B/FC6.9 (2 pcs for each bracket on cable package and 2 pcs on swing) Tightening torque: 2.6 Nm xx2100001466 xx2000001557 Continues on next page Product manual - IRB 1300 175 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued 6 Action Note Refit the axis-2 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001556 Routing the cable package in the lower arm Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the connector plate to the cable package. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001554 Continues on next page 176 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued 3 Action Note Check the axis-3 cable protector. Replace if damaged. Grease: 3HAC029132-001 Plastic cable protector, axis 3: 3HAC064693-001 Note If replaced, apply grease to the axis-3 cable protector before refitting. xx2000001568 Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 2.6 Nm xx2000001552 4 Route the cable package through the lower arm support and up into the housing. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001569 Reconnecting the axis-2 and -3 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001551 Continues on next page Product manual - IRB 1300 177 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 3 Note Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001549 4 Reconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip See the number markings on the connectors for help to find the corresponding connector. 5 Refit the connector plate to the lower arm. xx2000001550 Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001548 Securing the cable package in the lower arm Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 178 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued 2 Action Note Refit the cable bracket. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs on the cable package and 2 pcs on lower arm) Tightening torque: 2.6 Nm xx2100001465 xx2000001553 Routing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Slip the axis-4 cable protector over the cable package. Plastic cable protector, axis 4: 3HAC064694-001: xx2000001570 Continues on next page Product manual - IRB 1300 179 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 3 Note Insert the cable package through the hollow tube of the axis-4 gearbox, into the extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4) and into the tubular. Make sure that: • the air hoses are facing the axis-3 gearbox side in the hollow tube of axis-4 gearbox. CAUTION xx2000001571 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Securing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the axis-4 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001546 Reconnecting the axis-4 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001545 Continues on next page 180 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 3 Note Reconnect the connectors. • FB4 • MP4 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001544 4 Route and secure the cabling with a cable strap. Note The motor cablings have another strap fixed. Pay attention to the location where the new strap to be fixed, see the figure as a guidance. CAUTION xx2000001543 Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the connector plate. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001542 Routing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 181 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 2 Note Refit the second semicircular bracket to the tubu- Screw: M4x8 12.9 Lafre lar. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001749 3 Route the cablings. • Leave the CP/CS connectors and motor connectors out from the tubular support, and Ethernet connectors and air hoses out from the process hub. • The air hoses are facing upside in the semicircular bracket. Reconnecting the air hoses and Ethernet cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Reconnect the air hoses. Note See the number markings on the air hoses for help to find the corresponding air hoses. xx2000001539 3 For robots with Ethernet cabling Access the connector from the process hub and reconnect the connector. • J1.C2 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001540 Continues on next page 182 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Reconnecting the CP/CS cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the connectors to the connector plate. xx2000001537 3 For robots with CP/CS cabling Reconnect the connectors. • J1.C1 • J1.C3 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001536 Reconnecting the axis-5 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001535 Continues on next page Product manual - IRB 1300 183 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 3 Note Reconnect the connectors. • FB5 • MP5 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001534 Reconnecting the axis-6 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001533 3 Reconnect the connectors. • FB6 • MP6 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001532 Refitting the process hub Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 184 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued 2 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for process hub: 3HAC070887-001 xx2000002512 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolts. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002513 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the process hub. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001538 Securing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 185 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 2 Note Refit the first semicircular bracket to fix the cable Screw: M4x12 12.9 Lafre package. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001748 3 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each plate) Tightening torque: 1.3 Nm xx2000001531 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001530 Reconnecting the brake release connector Action Note 1 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. Continues on next page 186 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 2 Note Reconnect the connector. • R2.BRU Tip See the number markings on the connectors for help to find the corresponding connector. xx2100001480 3 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. Reconnecting the earth cable Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for base cover: 3HAC067819-001 xx2000002526 3 Reconnect the earth cable. xx2000001574 Continues on next page Product manual - IRB 1300 187 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 4 Note Valid for cabling with bottom interface (option Screw: M4x10 12.9 Lafre 3309-1) 2C2B/FC6.9 (8 pcs) Refit the base rear cover. Tightening torque: 2.6 Nm xx2000001573 Reconnecting the SMB connectors Action Note 1 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 2 For robots with protection type Clean Room Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for SMB cover: 3HAC067820-001 xx2000002508 4 Reconnect the connectors. • SMB.J1 • SMB.J2 • R2.SMB Tightening torque: 0.3 Nm Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001504 Continues on next page 188 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 5 Note Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 6 Refit the SMB cover to the base. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 2.6 Nm xx2000001503 Refitting the connector interface plate Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for base cover: 3HAC067819-001 xx2000002514 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolt. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002515 Continues on next page Product manual - IRB 1300 189 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 4 Note Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the connector interface plate to the base. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 2.6 Nm Valid for cabling with rear interface xx2000001558 Valid for cabling with bottom interface (option 3309-1) xx2000001575 Refitting the covers Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 190 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action 2 Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gaskets. • Tubular support cover (A) • Housing cover (B) • Lower arm support cover (C) • Swing support cover (D) • Swing top cover (E) Replace if damaged. xx2000002497 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the covers. • Gasket for tubular support cover (A) • Gasket for housing cover (B) • Gasket for lower arm support cover (C) • Gasket for swing support cover (D) • Gasket for swing top cover (E) Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001572 Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. Continues on next page Product manual - IRB 1300 191 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.1 Replacing the cable package Continued Action Note 3 DANGER Make sure all safety requirements are met when performing the first test run. 192 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.2 Replacing the SMB unit 5.3.2 Replacing the SMB unit Location of the SMB unit The SMB unit is located as shown in the figure. xx2000001494 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Serial measurement unit 3HAC063968-001 SMB cover 3HAC076475-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. SMB cover, Clean Room 3HAC077839-001 Used with protection type Clean Room. Gasket for SMB cover 3HAC067820-001 Not used with protection class IP40. Replace if damaged. Continues on next page Product manual - IRB 1300 193 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.2 Replacing the SMB unit Continued Spare part Article number Note Battery pack 3HAC044075-001 Battery includes protection circuits. Only replace with the specified spare part or an ABB-approved equivalent. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Consumable Article number Note Cable straps - Grease 3HAC029132-001 Required consumables and wear parts FM 222 Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page 194 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.2 Replacing the SMB unit Continued Removing the SMB unit Use these procedures to remove the SMB unit. Preparations before removing the SMB unit Action Note 1 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 Jog the robot to the synchronization position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Disconnecting the SMB connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 195 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.2 Replacing the SMB unit Continued Action Note 2 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 3 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 4 Remove the SMB cover attachment screws and carefully open the cover. CAUTION Clean cover from metal residues before opening. Metal residues can cause shortage on the boards which can result in hazardous failures. CAUTION xx2000001503 There are cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. 5 Disconnect the connectors. • SMB.J1 • SMB.J2 • R2.SMB Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. 6 xx2000001504 Remove the SMB cover completely from the base. Removing the battery pack Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 196 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.2 Replacing the SMB unit Continued Action Note 2 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 3 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 4 Disconnect the battery cable. xx2000001505 5 Remove the battery pack by cutting the cable strap. xx2000001506 Removing the SMB unit Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. Continues on next page Product manual - IRB 1300 197 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.2 Replacing the SMB unit Continued Action Note 3 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 4 Remove the screws. xx2000001507 Refitting the SMB unit Use these procedures to refit the SMB unit. Refitting the SMB unit Action Note 1 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 2 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 3 Refit the screws. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.3 Nm xx2000001507 Continues on next page 198 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.2 Replacing the SMB unit Continued Refitting the battery pack Action Note 1 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 2 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 3 Secure the battery pack using the cable strap. xx2000001506 4 Reconnect the battery cable. xx2000001505 Reconnecting the SMB connectors Action Note 1 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 2 For robots with protection type Clean Room Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 199 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.2 Replacing the SMB unit Continued 3 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for SMB cover: 3HAC067820-001 xx2000002508 4 Reconnect the connectors. • SMB.J1 • SMB.J2 • R2.SMB Tightening torque: 0.3 Nm Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001504 5 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 6 Refit the SMB cover to the base. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 2.6 Nm xx2000001503 Continues on next page 200 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.2 Replacing the SMB unit Continued Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. 3 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1300 201 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.3 Replacing the brake release unit 5.3.3 Replacing the brake release unit Location of the brake release unit The brake release unit is located as shown in the figure. xx1900001653 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Brake release unit 3HAC073296-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Brake release unit, Clean Room 3HAC077826-001 Used with protection type Clean Room. Gasket for brake release unit 3HAC070274-001 Not used with protection class IP40. Replace if damaged. Continues on next page 202 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.3 Replacing the brake release unit Continued Required tools and equipment Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply Used to release the motor brakes. - Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Removing the brake release unit Use these procedures to remove the brake release unit. Preparations before removing the brake release unit Action 1 Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1300 203 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.3 Replacing the brake release unit Continued Action 2 Note Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Removing the brake release unit Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. Continues on next page 204 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.3 Replacing the brake release unit Continued Action Note 3 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 4 Remove the screws and carefully open the cover. CAUTION Clean cover from metal residues before opening. Metal residues can cause shortage on the boards which can result in hazardous failures. CAUTION xx2000001577 There are cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. 5 Cut the cable strap. 6 Disconnect the connector. • R2.BRU Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001578 7 Remove the brake release unit completely from the base. Refitting the brake release unit Use these procedures to refit the brake release unit. Refitting the brake release unit Action Note 1 ELECTROSTATIC DISCHARGE (ESD) The unit is sensitive to ESD. Before handling the unit read the safety information in section The unit is sensitive to ESD on page 50. 2 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 205 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.3 Replacing the brake release unit Continued 3 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for brake release unit: 3HAC070274-001 xx2000002509 4 Reconnect the connector. • R2.BRU Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001578 5 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 6 Refit the brake release unit. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 2.6 Nm xx2000001577 Continues on next page 206 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.3.3 Replacing the brake release unit Continued Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. 3 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1300 207 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base 5.4 Swing and base 5.4.1 Replacing the base Location of the base The base is located as shown in the figure. xx2000001473 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Base 3HAC073029-001 Used for IRB 1300-11/0.9, IRB 1300-10/1.15 and IRB 1300-7/1.4. Used with protection classes IP40 and IP67. Base, Clean Room 3HAC077806-001 Used for IRB 1300-11/0.9, IRB 1300-10/1.15 and IRB 1300-7/1.4. Used with protection type Clean Room. Continues on next page 208 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Spare part Article number Note Base, Foundry Plus 3HAC077840-001 Used for IRB 1300-11/0.9, IRB 1300-10/1.15 and IRB 1300-7/1.4. Used with protection type Foundry Plus. Base (IRB 1300-12/1.4) 3HAC082393-001 Used for IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Base, Clean Room (IRB 130012/1.4) 3HAC082394-001 Used for IRB 1300-12/1.4. Used with protection type Clean Room. Base, Foundry Plus (IRB 130012/1.4) 3HAC082395-001 Used for IRB 1300-12/1.4. Used with protection type Foundry Plus. Gear unit, axis 1 3HAC063187-001 O-ring on axis-1 gear unit 3HAC063187-007 Motor unit, axis 1 3HAC073039-001 O-ring on motor unit 3HAC061327-037 Radial sealing 3HAC066433-001 Radial sealing 3HAC070148-002 Quick coupling 3HAC074630-001 Gasket on swing 3HAC067626-001 Mechanical stop, axis 1, fixed block 3HAC064478-001 Replace if damaged. Mechanical stop, axis 1, slider 3HAC065755-001 Replace if damaged. Main cable harness, S, basic 3HAC073303-001 Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, S (CP/CS and 3HAC073304-001 air hose, without Ethernet) Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, S (CP/CS and 3HAC073305-001 air hose, with Ethernet) Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, M, basic Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. 3HAC073300-001 Continues on next page Product manual - IRB 1300 209 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Spare part Article number Note Main cable harness, M (CP/CS and 3HAC073301-001 air hose, without Ethernet) Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, M (CP/CS and 3HAC073302-001 air hose, with Ethernet) Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L, basic 3HAC073297-001 Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L (CP/CS and 3HAC073298-001 air hose, without Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L (CP/CS and 3HAC073299-001 air hose, with Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic 3HAC073306-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, S, basic, Clean Room 3HAC077833-001 Used with IRB 1300-11/0.9. Used with protection type Clean Room. Main cable harness, S, Clean 3HAC077834-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-11/0.9. Used with protection type Clean Room. Main cable harness, S, Clean Room (CP/CS and air hose, with Ethernet) Used with IRB 1300-11/0.9. Used with protection type Clean Room. 3HAC077835-001 Continues on next page 210 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Spare part Article number Note Main cable harness, M, basic, Clean Room 3HAC077830-001 Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, M, Clean 3HAC077831-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, M, Clean Room (CP/CS and air hose, with Ethernet) 3HAC077832-001 Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, L, basic, Clean 3HAC077827-001 Room Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Main cable harness, L, Clean 3HAC077828-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Main cable harness, L, Clean Room (CP/CS and air hose, with Ethernet) 3HAC077829-001 Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Plastic cable protector, axis 2 3HAC067816-001 Plastic cable protector, axis 3 3HAC064693-001 Plastic cable protector, axis 4 3HAC064694-001 Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, short 3HAC073095-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page Product manual - IRB 1300 211 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Spare part Article number Note Swing cover, long 3HAC073096-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing top cover 3HAC073091-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Base cover 3HAC073090-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. SMB cover 3HAC076475-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Brake release unit 3HAC073296-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Swing cover, short, Clean Room 3HAC077824-001 Used with protection type Clean Room. Swing cover, long, Clean Room 3HAC077825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Swing top cover, Clean Room 3HAC077820-001 Used with protection type Clean Room. Base cover, Clean Room 3HAC077819-001 Used with protection type Clean Room. SMB cover, Clean Room 3HAC077839-001 Used with protection type Clean Room. Brake release unit, Clean Room 3HAC077826-001 Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for SMB cover 3HAC067820-001 Not used with protection class IP40. Replace if damaged. Continues on next page 212 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Spare part Article number Note Gasket for brake release unit 3HAC070274-001 Not used with protection class IP40. Replace if damaged. Gasket for base cover 3HAC067819-001 Not used with protection class IP40. Replace if damaged. Gasket for base adapter 3HAC067818-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Gasket for swing support, short 3HAC067822-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing support, long 3HAC067823-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, short 3HAC067824-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, long 3HAC067825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Gasket for swing top cover 3HAC067821-001 Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Radial sealing on swing (to base) 3HAC070148-003 Used with protection types Clean Room and Foundry Plus. Replace if damaged. Continues on next page Product manual - IRB 1300 213 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Required tools and equipment Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Oil collecting vessel - The capacity of the vessel must be sufficient to take the complete amount of oil. Connector for quick coupling, with outlet pipe Used for draining and filling oil to axis-1 gearbox. Connector specification: G3/8 Oil dispenser - Includes pump with outlet pipe. Quick coupling assembly tool - Included in special toolkit 3HAC076396-001. Axis-1 gearbox assembly cap - Included in special toolkit 3HAC076396-001. Axis-1 gearbox/motor sealing pressfit tool - Included in special toolkit 3HAC076396-001. Axis-1 gearbox/motor sealing pressfit base - Included in special toolkit 3HAC076396-001. Roundsling, 1.7 m - Length: 1.7 m Lifting capacity: >400 kg Overhead crane - Special toolkit for IP67/Clean Room/Foundry Plus robots 3HAC078203-001 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. Consumable Article number Note Cable straps - Grease 3HAC029132-001 FM 222 Lubricating oil 3HAC032140-001 Kyodo Yushi TMO150 Required consumables Flange sealant for conical fittings - Loctite 577 Continues on next page 214 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Removing the base Use these procedures to remove the base. Preparations before removing the base Action Note 1 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Draining oil of axis-1 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. Continues on next page Product manual - IRB 1300 215 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action Note 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. 3 Place the oil collecting vessel underneath the quick coupling. xx2000001514 4 Remove the oil plugs and keep them opened to speed up the drainage. xx2000001513 5 Plug a G3/8 quick coupling connector with pipe to the quick coupling on base. 6 WARNING Used oil is hazardous material and must be disposed of in a safe way. See Decommissioning on page 747 for more information. 7 Drain the gearbox oil. Note Draining is time-consuming. Elapsed time varies depending on the temperature of the oil. 8 Remove the quick coupling connector and clean the pipe after the oil is drained. Note There will be some oil left in the gearbox after draining. Continues on next page 216 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued 9 Action Note Refit oil plugs. Tightening torque: 10 Nm Removing the complete cable package Follow the instructions detailed in Removing the cable package on page 155 to remove the complete cable package. Supporting the arm system with roundsling Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Run a roundsling around the lower arm. Roundsling, 1.7 m, Lifting capacity: >400 kg xx2000001651 4 CAUTION The arm system weighs 52 kg. All lifting accessories used must be sized accordingly! 5 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Continues on next page Product manual - IRB 1300 217 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action Note 6 WARNING Personnel must not, under any circumstances, be present under the suspended load. 7 Stretch the roundsling to take the weight of the arm system. Note Do not stretch the roundsling too much. Separating the arm system from base Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove screws and washers. xx2000000502 4 Lift the arm system little by little to separate the arm system from the base. xx2000001702 Continues on next page 218 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Removing the axis-1 mechanical stops Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Access the axis-1 mechanical stop slider from the swing. Put it aside for later refitting. xx2000001703 4 Remove the axis-1 mechanical stop fixed block. xx2000001693 Removing the base from foundation Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 219 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. 4 Loosen the base from the foundation by removing the foundation attachment screws. Removing the base covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Valid for cabling with rear interface Remove the base bottom cover together with the base adapter. xx2000001642 Removing the axis-1 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 220 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 WARNING When separating the motor from the gearbox, there may be pressure present in the gearbox, causing lubricant to spray from the opening. Before proceeding, please read the safety information in the section Gearbox lubricants (oil or grease) on page 29. 4 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. 5 Access the screws and washers securing the axis1 motor from the base bottom. xx2000001643 6 Remove the screws and washers. xx2000001644 Continues on next page Product manual - IRB 1300 221 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action 7 Note Carefully lift out the motor. xx2000001645 Removing the axis-1 gearbox Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing gearboxes will release axes. This means the axes can fall down. Make sure axes are well supported before removing gearboxes. 4 Remove the screws. xx2000001694 Continues on next page 222 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action 5 Note Pull out the gearbox. xx2000001695 Refitting the base Use these procedures to refit the base. Checking the radial sealings on the base Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealings on the base. Replace if damaged, as described below. xx2000001713 3 Place the new motor-side radial sealing in its groove in the base. The sealing lip is towards the swing side. Radial sealing: 3HAC066433-001 xx2000001714 Continues on next page Product manual - IRB 1300 223 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action 4 Note Place the pressfit base (A) against one side of the Axis-1 gearbox/motor sealing sealing and the pressfit tool (B) against the other pressfit base. Included in special side, as shown in the figures. toolkit 3HAC076396-001. xx2000001715 Axis-1 gearbox/motor sealing pressfit tool. Included in special toolkit 3HAC076396-001. xx2000001716 5 Fix the pressift tool with an M8 screw. xx2000001717 6 Screw the screw, little by little and evenly, to press the sealing into place. 7 Repeat steps 3 to 6 to replace the gearbox-side Radial sealing: 3HAC070148-002 radial sealing. Checking the quick coupling on the base Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 224 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued 2 Action Note Check the quick coupling. Replace if damaged. Quick coupling: 3HAC074630-001 xx2000001681 3 Use the quick coupling assembly tool to remove and refit the quick coupling. Apply flange sealing Loctite 577 on the mounting surfaces of the quick coupling and wipe clean if there is any overflowing Loctite 577. Quick coupling assembly tool. Included in special toolkit 3HAC076396-001. Tightening torque: N/A, tighten up properly. xx2000001335 Refitting the axis-1 gearbox Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the O-ring. Replace if damaged. O-ring on axis-1 gear unit: 3HAC063187-007 xx2000001696 Continues on next page Product manual - IRB 1300 225 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action 3 Note Put the axis-1 gearbox on the workbench with the Axis-1 gearbox assembly cap. Ingear side towards upside and place the assembly cluded in special toolkit cap to the gearbox. 3HAC076396-001. xx2000001709 4 Put the base onto the gearbox. xx2000001710 5 Turn the base together with the gearbox over to the standing position. xx2000001711 6 Remove the assembly cap. xx2000001712 Continues on next page 226 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued 7 Action Note Secure with screws. Screw: M6x65 12.9 Gleitmo 603+Geomet 500 (12 pcs) Tightening torque: 11.5 Nm xx2000001694 8 Mark the screws aligned with the oil openings. xx2000001698 Putting the base on its side Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 Put the base on its side for easily refitting the motor and base cover. Refitting the axis-1 motor Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1300 227 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued 3 Action Note Check the O-ring. Replace if damaged. O-ring on motor unit: 3HAC061327037 xx2000001646 4 Apply lubricating oil to the motor that has contact- Kyodo Yushi TMO150: 3HAC032140-001 ing area with the gearbox. xx2000001700 5 Orient the motor correctly and fit it into the swing. Motor orientation: orient the motor Make sure the motor is properly fit to gearbox. according to the figure below, in regard to the encircled motor connector. xx2000001647 6 Refit the screws and washers. Screw: M6x20 12.9 Gleitmo 603+Geomet 500 (4 pcs) Tightening torque: 10 Nm xx2000001644 Continues on next page 228 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Refitting the base covers Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Valid for cabling with rear interface Check the gasket. Replace if damaged. Gasket for base adapter: 3HAC067818-001 xx2000002510 3 Valid for cabling with rear interface Screw: M4x10 12.9 Lafre Refit the base bottom cover together with the base 2C2B/FC6.9 (8 pcs) adapter. Tightening torque: 2.6 Nm xx2000001642 Securing the base to the foundation Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Secure the base to the foundation with the attach- Attachment screws: M16x50, qualment screws and washers. ity: 8.8. Washers: 17 x 30 x 3, steel hardness class 200HV. Tightening Torque: 150 Nm±10 Nm. Check the radial sealing on the swing bottom (IP67, Clean Room and Foundry Plus) Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 229 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action 2 Note Check the radial sealing on the swing bottom. Replace if damaged, as described below. Note If the radial sealing requires to be replaced during the replacement of the base, remove the swing from the lower arm first. See Replacing the swing on page 237. xx2000002452 3 Place the pressfit support of the axis-1 sealing Pressfit support of the axis-1 sealassembly tool on the workbench, positioning as ing assembly tool, included in shown in the figure. Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002453 Continues on next page 230 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action 4 Note Turn the swing upside down and place it on to the pressfit support. Make sure the convex pins on the support are properly fitted into the holes on the swing. xx2000002454 xx2000002455 xx2000002456 5 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. Continues on next page Product manual - IRB 1300 231 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action 6 Note Fit the new sealing into the swing. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002457 xx2000002537 7 Fit the circular plate of the axis-1 sealing assembly Circular plate of the axis-1 sealing tool against the sealing and fix with four M8x145 assembly tool, included in Special screws. toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002458 xx2000002459 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. Continues on next page 232 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action 10 Note Check that the sealing is undamaged and properly fitted. Refitting the axis-1 mechanical stops Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the axis-1 mechanical stop fixed block. Screw: M4x25 12.9 Lafre 2C2B/FC6.9 (6 pcs) Tightening torque: 3.8 Nm xx2000001693 3 Apply grease to the axis-1 mechanical stop slider Grease: 3HAC029132-001 and refit it to the swing. xx2000001703 Securing the arm system to the base Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the gasket. Replace if damaged. Gasket on swing: 3HAC067626-001 xx2000001704 Continues on next page Product manual - IRB 1300 233 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action 3 Note Place the arm system slowly down to the base. xx2000001702 4 Align the oil plugs on the swing with the marked screws on the axis-1 gearbox. xx2000001699 5 Screw: M8x45 12.9 Gleitmo 603+Geomet 500 (8 pcs) Tightening torque: 36 Nm Secure with screws and washers. xx2000000502 Refitting the complete cable package Follow the instructions detailed in Refitting the cable package on page 171 to refit the complete cable package. Refilling oil to axis-1 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. Continues on next page 234 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action Note 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. 3 Open the oil plugs, one for filling and the other for venting. xx2000001513 4 WARNING Overfilling of gearbox lubricant can lead to internal over-pressure inside the gearbox which in turn may: • damage seals and gaskets • completely press out seals and gaskets • prevent the robot from moving freely. 5 Refill the gearbox with oil. Note Type of oil and total amount is detailed in Technical reference manual - Lubrication in gearboxes. The amount of oil to be filled depends on the amount previously being drained. 6 Refit the oil plugs. Tightening torque: 10 Nm Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. Continues on next page Product manual - IRB 1300 235 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.1 Replacing the base Continued Action Note 3 DANGER Make sure all safety requirements are met when performing the first test run. 236 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing 5.4.2 Replacing the swing Location of the swing The swing is located as shown in the figure. xx2000001474 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Swing, short 3HAC073040-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing, short, Clean Room 3HAC077807-001 Used for IRB 1300-11/0.9. Used with protection type Clean Room. Swing, long 3HAC073047-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page Product manual - IRB 1300 237 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Spare part Article number Note Swing, long, Clean Room 3HAC077809-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Swing support, short 3HAC073041-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing support, short, Clean Room 3HAC077808-001 Used for IRB 1300-11/0.9. Used with protection type Clean Room. Swing support, long 3HAC073052-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing support, long, Clean Room 3HAC077810-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Motor unit, axis 2 Used for IRB 1300-11/0.9, IRB 1300-10/1.15 and IRB 1300-7/1.4. 3HAC073078-001 Motor unit, axis 2 (IRB 1300-12/1.4) 3HAC082078-001 Used for IRB 1300-12/1.4. O-ring on motor unit 3HAC061327-037 Sealing ring, swing support side 3HAC065676-001 O-ring on swing 3HAC061327-036 Mechanical stop, block A 3HAC065651-001 Magnetic oil plug, G 1/4" 3HAC037925-001 Process hub, basic 3HAC073306-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Replace if damaged. Continues on next page 238 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Spare part Article number Note Plastic cable protector, axis 2 3HAC067816-001 Plastic cable protector, axis 3 3HAC064693-001 Plastic cable protector, axis 4 3HAC064694-001 Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, short 3HAC073095-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, long 3HAC073096-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing top cover 3HAC073091-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Swing cover, short, Clean Room 3HAC077824-001 Used with protection type Clean Room. Swing cover, long, Clean Room 3HAC077825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Swing top cover, Clean Room 3HAC077820-001 Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Continues on next page Product manual - IRB 1300 239 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Spare part Article number Note Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Gasket for swing support, short 3HAC067822-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing support, long 3HAC067823-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, short 3HAC067824-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, long 3HAC067825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Gasket for swing top cover 3HAC067821-001 Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Radial sealing on swing (to base) 3HAC070148-003 Used with protection types Clean Room and Foundry Plus. Replace if damaged. Radial sealing on swing (to lower 3HAC070148-004 arm) Not used with protection class IP40. Replace if damaged. Sealing ring, swing side 3HAC065675-001 Used with protection class IP67 and protection type Foundry Plus. O-ring on lower arm 3HAC061327-015 Not used with protection class IP40. Replace if damaged. Continues on next page 240 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Required tools and equipment Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Oil collecting vessel - The capacity of the vessel must be sufficient to take the complete amount of oil. Oil dispenser - Includes pump with outlet pipe. Roundsling, 1.7 m - Length: 1.7 m Lifting capacity: >400 kg Overhead crane - Special toolkit for IP67/Clean Room/Foundry Plus robots 3HAC078203-001 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. Consumable Article number Note Cable straps - Grease 3HAC029132-001 FM 222 Lubricating oil 3HAC032140-001 Kyodo Yushi TMO150 Locking liquid 3HAB7116-1 Loctite 243 Required consumables Removing the swing Use these procedures to remove the swing. Preparations before removing the swing Action 1 Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 241 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Jogging the robot to oil draining position Action 1 Note Jog the robot to the specified position: • Axis 1: 0° • Axis 2: -67.5 • Axis 3: 0° • Axis 4: 0° • Axis 5: 0° • Axis 6: No significance. xx2000001519 2 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Draining oil of axis-2 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. Continues on next page 242 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 3 Note Place the oil collecting vessel underneath the oil plug, draining. xx2000001515 4 Remove the oil plug, draining. xx2000001516 5 Plug a clean pipe to the oil plug, draining, with the other end to the oil collecting vessel. 6 Remove the oil plug, venting and keep it opened to speed up the drainage. xx2000001517 7 WARNING Used oil is hazardous material and must be disposed of in a safe way. See Decommissioning on page 747 for more information. 8 Drain the gearbox oil. Note Draining is time-consuming. Elapsed time varies depending on the temperature of the oil. Continues on next page Product manual - IRB 1300 243 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 9 Note Remove and clean the pipe after the oil is drained. Note There will be some oil left in the gearbox after draining. 10 Refit oil plugs. Tightening torque: 10 Nm Jogging the robot to zero position Action Note 1 Turn on the electric power to the robot. If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to Supplying power to connector R1.MP on page 66. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Removing the covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 244 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm support cover (C) • Swing covers (D) • Swing top cover (E) xx2000001722 Loosening the cables in the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Cut the cable straps. xx2000001530 Continues on next page Product manual - IRB 1300 245 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 4 Note Remove the connector plates. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001531 Disconnecting the axis-6 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP6 • FB6 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001532 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001533 Continues on next page 246 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Disconnecting the axis-5 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP5 • FB5 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001534 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001535 Disconnecting CP/CS cabling (if equipped) Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 247 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 For robots with CP/CS cabling Disconnect the connectors. • J1.C1 • J1.C3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001536 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001537 Separating the cable package from the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 248 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 3 Note Remove the first semicircular bracket that fixes the cable package. xx2000001748 4 Remove the second semicircular bracket from the tubular. xx2000001749 Removing the process hub Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws and carefully open the cover. CAUTION There is cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. xx2000001538 Continues on next page Product manual - IRB 1300 249 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 4 Note Disconnect the air hoses. xx2000001539 5 For robots with Ethernet cabling Access the connector from the process hub and disconnect the connector. • J1.C2 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001540 Tip The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Disconnecting the axis-4 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 250 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001542 4 Cut the cable strap. Note The motor cablings have another strap fixed. Always cut the strap that fixes the cable package to the plate. xx2000001543 5 Disconnect the connectors. • MP4 • FB4 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001544 6 Snap loose and remove the male head of the connectors from the connector plate. xx2000001545 Continues on next page Product manual - IRB 1300 251 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Separating the cable package from the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the axis-4 cable protector. xx2000001546 Disconnecting the axis-2 and -3 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate, as shown in following step. xx2000001548 Continues on next page 252 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 4 Note Cut the cable straps. xx2000001549 5 Disconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. 6 xx2000001550 Snap loose and remove the male head of the connectors from the connector plate. xx2000001551 Separating the cable package from the lower arm Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 253 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 3 Note Remove the cable bracket from the lower arm first and then from the cable package. xx2000001553 xx2100001465 4 Remove the connector plate. xx2000001554 Separating the cable package from the swing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 254 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 3 Note Remove the axis-2 cable protector. xx2000001556 4 Remove the cable brackets from the swing first and then from the cable package. xx2000001557 xx2100001466 Pulling out the cable package Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Wrap the connectors with the masking tape. Continues on next page Product manual - IRB 1300 255 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 4 Note Pull the cable package out to the swing support. xx2000001683 Removing the swing support Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the swing support. Tip If the lower arm support is hard to loosen from the swing, use a plastic hammer to knock on the lower arm support lightly. xx2000001684 Supporting the lower and upper arms with roundslings Note The lower and upper arms include the lower arm, housing, extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4), tubular and tilt unit. Continues on next page 256 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Run two roundslings between the housing and the lower arm. Roundsling, 1.7 m (2 pcs), Lifting capacity: >400 kg xx2000001685 4 CAUTION The lower and upper arms weighs 38 kg. All lifting accessories used must be sized accordingly! 5 WARNING The robot is likely to be mechanically unstable if not secured to the foundation! 6 WARNING Personnel must not, under any circumstances, be present under the suspended load. Continues on next page Product manual - IRB 1300 257 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 7 Note Stretch the roundslings to take the weight of the lower and upper arms. Note Do not stretch the roundslings too much. Separating the swing from the lower arm Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws. xx2000001686 4 Separate the swing from the lower arm. Tip If the swing is hard to loosen from the lower arm, use a plastic hammer to knock on the swing lightly. xx2000001687 Continues on next page 258 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Separating the swing from the base Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Separate the swing from the base. Note The axis-1 mechanical stop slider is accessible from the swing. Put it aside for later refitting. xx2000000502 xx2000001703 4 Pull the cable package completely out from the swing. Refitting the swing Use these procedures to refit the swing. Check the radial sealing on the swing bottom (IP67, Clean Room and Foundry Plus) Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 259 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 2 Note Check the radial sealing on the swing bottom. Replace if damaged, as described below. Note If the radial sealing requires to be replaced during the replacement of the base, remove the swing from the lower arm first. See Replacing the swing on page 237. xx2000002452 3 Place the pressfit support of the axis-1 sealing Pressfit support of the axis-1 sealassembly tool on the workbench, positioning as ing assembly tool, included in shown in the figure. Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002453 Continues on next page 260 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 4 Note Turn the swing upside down and place it on to the pressfit support. Make sure the convex pins on the support are properly fitted into the holes on the swing. xx2000002454 xx2000002455 xx2000002456 5 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. Continues on next page Product manual - IRB 1300 261 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 6 Note Fit the new sealing into the swing. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002457 xx2000002537 7 Fit the circular plate of the axis-1 sealing assembly Circular plate of the axis-1 sealing tool against the sealing and fix with four M8x145 assembly tool, included in Special screws. toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002458 xx2000002459 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. Continues on next page 262 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 10 Note Check that the sealing is undamaged and properly fitted. Check the radial sealing on the swing top (Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the swing top. Replace if damaged, as described below. xx2000002460 3 Fit the big circular plate of the axis-2 sealing as- Big circular plate of the axis-2 sembly tool to the swing (opposite side of the ra- sealing assembly tool, included in Special toolkit for IP67/Clean dial sealing) with three M4x12 screws. Room/Foundry Plus robots (3HAC078203-001). xx2000002461 4 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. Continues on next page Product manual - IRB 1300 263 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 5 Note Fit the new sealing into the swing. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002462 xx2000002537 6 For robots with protection type Foundry Plus (option 3352-10) Place the ring of the axis-2 sealing assembly tool against the sealing. Ring of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002463 xx2000002562 Continues on next page 264 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued 7 Action Note Fit the small circular plate of the axis-2 sealing assembly tool and fix with three M6x75 screws. Small circular plate of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002464 xx2000002465 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Refitting the swing to the base Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the axis-2 mechanical stops. Replace if damaged. See Replacing the axis-2 mechanical stops on page 293. Continues on next page Product manual - IRB 1300 265 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued 3 Action Note Check the oil plugs. Replace if damaged. Magnetic oil plug, G 1/4": 3HAC037925-001 Tightening torque: 10 Nm xx2000001723 4 Check the gasket. Replace if damaged. Gasket on swing: 3HAC067626-001 xx2000001704 5 Apply grease to the axis-1 mechanical stop slider Grease: 3HAC029132-001 and refit it to the swing. xx2000001703 6 Route the cable package through the swing and out from the swing support side. 7 Place the swing down to the base. 8 Align the oil plugs on the swing with the marked screws on the axis-1 gearbox. xx2000001699 Continues on next page 266 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued 9 Action Note Secure with screws and washers. Screw: M8x45 12.9 Gleitmo 603+Geomet 500 (8 pcs) Tightening torque: 36 Nm xx2000000502 Refitting the swing to the lower arm Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) Check the sealing ring. Replace if damaged. For robots with protection type Foundry Plus (option 3352-10) Check the sealing ring and the O-ring. Replace if damaged. O-ring on lower arm: 3HAC061327015 Sealing ring, swing side: 3HAC065675-001 Screw: M4x12 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 3.8 Nm For robots with protection class IP67 (option 3350-670) xx2000002516 For robots with protection type Foundry Plus (option 3352-10) xx2000002527 Continues on next page Product manual - IRB 1300 267 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued 3 Action Note Check the O-ring. Replace if damaged. O-ring on swing: 3HAC061327-036 xx2000001750 4 Refit the swing to the lower arm. M10 screws Screw: M10x25 12.9 Gleitmo 603+Geomet 500 (6 pcs) Tightening torque: 72 Nm M6 screws Screw: M6x20 12.9 Gleitmo 603+Geomet 500 (3 pcs) Tightening torque: 14 Nm xx2000001686 Releasing the weight support for lower and upper arms Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 WARNING Personnel must not, under any circumstances, be present under the suspended load. 3 Make sure the lower and upper arms are firmly secured with the swing. 4 Remove the roundslings. Continues on next page 268 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Check the radial sealing on the swing support (IP67, Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the swing support. Replace if damaged, as described below. xx2000002466 3 Fit the big circular plate of the axis-2 sealing as- Big circular plate of the axis-2 sembly tool to the swing support (opposite side sealing assembly tool, included in of the radial sealing) with three M4x12 screws. Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002467 4 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. Continues on next page Product manual - IRB 1300 269 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 5 Note Fit the new sealing into the swing support. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002468 xx2000002537 6 For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) Place the ring of the axis-2 sealing assembly tool against the sealing. Ring of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002469 xx2000002562 Continues on next page 270 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued 7 Action Note Fit the small circular plate of the axis-2 sealing assembly tool and fix with three M6x75 screws. Small circular plate of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002470 xx2000002471 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Refitting the swing support Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the sealing ring. Replace if damaged. Sealing ring, swing support side: 3HAC065676-001 Screw: M4x12 12.9 Lafre 2C2B/FC6.9 (16 pcs) Tightening torque: 3.8 Nm xx2000001692 Continues on next page Product manual - IRB 1300 271 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued 3 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the O-ring. Replace if damaged. O-ring on lower arm: 3HAC061327015 xx2000002518 4 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for swing support, short: 3HAC067822-001 Gasket for swing support, long: 3HAC067823-001 xx2000002520 5 Route the cable package through the swing support. Make sure that: • the air hoses are facing the SMB side in the hollow tube of axis-1 gearbox. • the cable package is out from the hole near the base rear, as circled in the figure. CAUTION xx2000001745 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001747 Continues on next page 272 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued 6 Action Note Refit the swing support. Screw: M8x40 12.9 Gleitmo 603+Geomet 500 (7 pcs) Tightening torque: 36 Nm xx2000001684 7 Apply grease to the axis-2 cable protector and slip it over the cable harness. Grease: 3HAC029132-001 Plastic cable protector, axis 2: 3HAC067816-001 xx2000001567 Securing the cable package in the swing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Route the cable package up into the lower arm. Make sure that the the air hoses are facing outside in the axis-2 cable protector, see the figure as a guidance for the cable twisting way. xx2000001746 Continues on next page Product manual - IRB 1300 273 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued 3 Action Note Refit the cable brackets. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each bracket on cable package and 2 pcs on swing) Tightening torque: 2.6 Nm xx2100001466 xx2000001557 4 Refit the axis-2 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001556 Routing the cable package in the lower arm Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 274 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued 2 Action Note Refit the connector plate to the cable package. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001554 3 Check the axis-3 cable protector. Replace if damaged. Grease: 3HAC029132-001 Plastic cable protector, axis 3: 3HAC064693-001 Note If replaced, apply grease to the axis-3 cable protector before refitting. xx2000001568 Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 2.6 Nm xx2000001552 4 Route the cable package through the lower arm support and up into the housing. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001569 Continues on next page Product manual - IRB 1300 275 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Reconnecting the axis-2 and -3 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001551 3 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001549 4 Reconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip See the number markings on the connectors for help to find the corresponding connector. 5 Refit the connector plate to the lower arm. xx2000001550 Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001548 Continues on next page 276 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Securing the cable package in the lower arm Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the cable bracket. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs on the cable package and 2 pcs on lower arm) Tightening torque: 2.6 Nm xx2100001465 xx2000001553 Routing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Slip the axis-4 cable protector over the cable package. Plastic cable protector, axis 4: 3HAC064694-001: xx2000001570 Continues on next page Product manual - IRB 1300 277 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 3 Note Insert the cable package through the hollow tube of the axis-4 gearbox, into the extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4) and into the tubular. Make sure that: • the air hoses are facing the axis-3 gearbox side in the hollow tube of axis-4 gearbox. CAUTION xx2000001571 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Securing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the axis-4 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001546 Reconnecting the axis-4 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001545 Continues on next page 278 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 3 Note Reconnect the connectors. • FB4 • MP4 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001544 4 Route and secure the cabling with a cable strap. Note The motor cablings have another strap fixed. Pay attention to the location where the new strap to be fixed, see the figure as a guidance. CAUTION xx2000001543 Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the connector plate. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001542 Routing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 279 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 2 Note Refit the second semicircular bracket to the tubu- Screw: M4x8 12.9 Lafre lar. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001749 3 Route the cablings. • Leave the CP/CS connectors and motor connectors out from the tubular support, and Ethernet connectors and air hoses out from the process hub. • The air hoses are facing upside in the semicircular bracket. Reconnecting the air hoses and Ethernet cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Reconnect the air hoses. Note See the number markings on the air hoses for help to find the corresponding air hoses. xx2000001539 3 For robots with Ethernet cabling Access the connector from the process hub and reconnect the connector. • J1.C2 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001540 Continues on next page 280 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Reconnecting the CP/CS cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the connectors to the connector plate. xx2000001537 3 For robots with CP/CS cabling Reconnect the connectors. • J1.C1 • J1.C3 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001536 Reconnecting the axis-5 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001535 Continues on next page Product manual - IRB 1300 281 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 3 Note Reconnect the connectors. • FB5 • MP5 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001534 Reconnecting the axis-6 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001533 3 Reconnect the connectors. • FB6 • MP6 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001532 Refitting the process hub Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 282 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued 2 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for process hub: 3HAC070887-001 xx2000002512 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolts. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002513 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the process hub. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001538 Securing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 283 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 2 Note Refit the first semicircular bracket to fix the cable Screw: M4x12 12.9 Lafre package. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001748 3 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each plate) Tightening torque: 1.3 Nm xx2000001531 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001530 Refitting the covers Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 284 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 2 Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gaskets. • Gasket for tubular support cover (A) • Gasket for housing cover (B) • Gasket for lower arm support cover (C) • Gasket for swing covers (D) • Gasket for swing top cover (E) Replace if damaged. xx2000002500 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm support cover (C) • Swing covers (D) • Swing top cover (E) Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001722 Jogging the robot to oil filling position Action 1 Note Turn on the electric power to the robot. If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to Supplying power to connector R1.MP on page 66. Continues on next page Product manual - IRB 1300 285 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 2 Note Jog the robot to the specified position: • Axis 1: 0° • Axis 2: -67.5 • Axis 3: 0° • Axis 4: 0° • Axis 5: 0° • Axis 6: No significance. xx2000001519 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Refilling oil to axis-2 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. Continues on next page 286 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action 3 Note Open the upper oil plug. Note The lower oil plug has to be closed; otherwise, the oil may leak before required oil amount is filled. xx2000001518 A Oil plug, opened B Oil plug, closed 4 WARNING Overfilling of gearbox lubricant can lead to internal over-pressure inside the gearbox which in turn may: • damage seals and gaskets • completely press out seals and gaskets • prevent the robot from moving freely. 5 Refill the gearbox with oil. Note Type of oil and total amount is detailed in Technical reference manual - Lubrication in gearboxes. The amount of oil to be filled depends on the amount previously being drained. CAUTION Oil filling must be slow to make sure air venting is fluent. 6 Inspect the oil level by measuring the level at the upper oil plug hole. Required oil level: within the range of 64 mm to 69 mm below the edge of the oil plug hole. CAUTION The oil level sinks when the oil fills all cavities in the gearbox. Wait until the oil stops sinking, before measuring the oil level. xx2000001580 7 Refit the oil plug. Tightening torque: 10 Nm Continues on next page Product manual - IRB 1300 287 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action Note 8 DANGER Make sure all safety requirements are met when performing the first test run. Jogging the robot to zero position Action Note 1 Turn on the electric power to the robot. If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to Supplying power to connector R1.MP on page 66. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. Continues on next page 288 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.2 Replacing the swing Continued Action Note 3 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1300 289 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.3 Replacing the axis-1 mechanical stops 5.4.3 Replacing the axis-1 mechanical stops Location of the mechanical stops The mechanical stops are located as shown in the figure. xx2000000406 A Mechanical stop, axis 1, slider B Mechanical stop, axis 1, fixed block Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Mechanical stop, axis 1, fixed block 3HAC064478-001 Replace if damaged. Mechanical stop, axis 1, slider 3HAC065755-001 Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Continues on next page 290 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.3 Replacing the axis-1 mechanical stops Continued Equipment Article number Note Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Roundsling, 1.7 m - Length: 1.7 m Lifting capacity: >400 kg Overhead crane - Special toolkit for IP67/Clean Room/Foundry Plus robots 3HAC078203-001 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. Replacement of axis-1 mechanical stops The axis-1 mechanical stops, both block and slider, are accessible after removing the base, see Replacing the base on page 208. Product manual - IRB 1300 291 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.4 Replacing the axis-2 mechanical stops 5.4.4 Replacing the axis-2 mechanical stops Location of the mechanical stops The mechanical stops are located as shown in the figure. xx2000000407 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Mechanical stop, block A 3HAC065651-001 Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Consumable Article number Note Locking liquid 3HAB7116-1 Loctite 243 Required tools and equipment Required consumables Continues on next page 292 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.4.4 Replacing the axis-2 mechanical stops Continued Replacing the axis-2 mechanical stops Action 1 Note Jog the robot to a position where the mechanical stops are most easily accessed. 2 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 3 Remove the mechanical stops. xx2000000506 4 Discard the old stops and refit with new ones. 5 Apply a little Loctite 243 to the screws. Mechanical stop, block A: 3HAC065651-001 (2 pcs) Note If there is locking liquid residues on the screw, please clean it before refitting. Remove residual locking liquid after refitting. 6 Secure the mechanical stops. Product manual - IRB 1300 Screw: M4x16 stainless steel (1 pcs per stop) Tightening torque: 1 Nm 293 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm 5.5 Upper and lower arms 5.5.1 Replacing the lower arm Location of the lower arm The lower arm is located as shown in the figure. xx2000001475 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Lower arm, short 3HAC073073-001 Used for IRB 1300-11/0.9. Used with protection class IP40 and protection type Foundry Plus. Lower arm, short, IP67 3HAC077798-001 Used for IRB 1300-11/0.9. Used with protection class IP67. Lower arm, short, Clean Room 3HAC077811-001 Used for IRB 1300-11/0.9. Used with protection type Clean Room. Continues on next page 294 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Spare part Article number Note Lower arm, long 3HAC073074-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection class IP40 and protection type Foundry Plus. Lower arm, long, IP67 3HAC077799-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection class IP67. Lower arm, long, Clean Room 3HAC077812-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Lower arm support 3HAC073076-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm support, Clean Room 3HAC077813-001 Used with protection type Clean Room. Swing support, short 3HAC073041-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing support, short, Clean Room 3HAC077808-001 Used for IRB 1300-11/0.9. Used with protection type Clean Room. Swing support, long 3HAC073052-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing support, long, Clean Room 3HAC077810-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Gear unit, axis 2 3HAC064977-001 Motor unit, axis 2 3HAC073078-001 Motor unit, axis 2 (IRB 1300-12/1.4) 3HAC082078-001 O-ring on motor unit 3HAC061327-037 Sealing ring, swing support side 3HAC065676-001 O-ring on swing 3HAC061327-036 Motor unit, axis 3 3HAC073086-001 Used for IRB 1300-11/0.9, IRB 1300-10/1.15 and IRB 1300-7/1.4. Used for IRB 1300-12/1.4. Used for IRB 1300-11/0.9, IRB 1300-10/1.15 and IRB 1300-7/1.4. Motor unit, axis 3 (IRB 1300-12/1.4) 3HAC082079-001 Used for IRB 1300-12/1.4. Resolver cover on motor (IRB 1300-12/1.4) 3HAC060261-001 Used for IRB 1300-12/1.4. Timing belt, axis 3 3HAC067040-001 Continues on next page Product manual - IRB 1300 295 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Spare part Article number Note Mechanical stop, block A 3HAC065651-001 Replace if damaged. Mechanical stop, block B 3HAC065671-001 Used for axis 3 of IRB 130010/1.15. Replace if damaged. Magnetic oil plug, G 1/4" 3HAC037925-001 Process hub, basic 3HAC073306-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Plastic cable protector, axis 2 3HAC067816-001 Plastic cable protector, axis 3 3HAC064693-001 Plastic cable protector, axis 4 3HAC064694-001 Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, short 3HAC073095-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, long 3HAC073096-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page 296 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Spare part Article number Note Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Swing cover, short, Clean Room 3HAC077824-001 Used with protection type Clean Room. Swing cover, long, Clean Room 3HAC077825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm support 3HAC067826-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Gasket for swing support, short 3HAC067822-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing support, long 3HAC067823-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, short 3HAC067824-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, long 3HAC067825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Continues on next page Product manual - IRB 1300 297 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Spare part Article number Note Radial sealing on swing (to lower 3HAC070148-004 arm) Not used with protection class IP40. Replace if damaged. Radial sealing on lower arm 3HAC070148-005 Not used with protection class IP40. Replace if damaged. Sealing ring, swing side 3HAC065675-001 Used with protection class IP67 and protection type Foundry Plus. O-ring on lower arm 3HAC061327-015 Not used with protection class IP40. Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Oil collecting vessel - The capacity of the vessel must be sufficient to take the complete amount of oil. Oil dispenser - Includes pump with outlet pipe. Guide pin for axis-2 gearbox - Included in special toolkit 3HAC076396-001. Sonic tension meter - Used for measuring the timing belt tension. Special toolkit for IP67/Clean Room/Foundry Plus robots 3HAC078203-001 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. Consumable Article number Note Cable straps - Grease 3HAC029132-001 FM 222 Lubricating oil 3HAC032140-001 Kyodo Yushi TMO150 Locking liquid 3HAB7116-1 Loctite 243 Required consumables Continues on next page 298 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Removing the lower arm Use these procedures to remove the lower arm. Preparations before removing the lower arm Action 1 Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Jogging the robot to oil draining position Action 1 Note Jog the robot to the specified position: • Axis 1: 0° • Axis 2: -67.5 • Axis 3: 0° • Axis 4: 0° • Axis 5: 0° • Axis 6: No significance. xx2000001519 2 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Draining oil of axis-2 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. Continues on next page Product manual - IRB 1300 299 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action Note 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. 3 Place the oil collecting vessel underneath the oil plug, draining. xx2000001515 4 Remove the oil plug, draining. xx2000001516 5 Plug a clean pipe to the oil plug, draining, with the other end to the oil collecting vessel. 6 Remove the oil plug, venting and keep it opened to speed up the drainage. xx2000001517 7 WARNING Used oil is hazardous material and must be disposed of in a safe way. See Decommissioning on page 747 for more information. Continues on next page 300 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 8 Note Drain the gearbox oil. Note Draining is time-consuming. Elapsed time varies depending on the temperature of the oil. 9 Remove and clean the pipe after the oil is drained. Note There will be some oil left in the gearbox after draining. 10 Refit oil plugs. Tightening torque: 10 Nm Jogging the robot to zero position Action Note 1 Turn on the electric power to the robot. If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to Supplying power to connector R1.MP on page 66. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 1300 301 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Removing the covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm covers (C) • Swing covers (D) xx2000001724 Loosening the cables in the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 302 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 3 Note Cut the cable straps. xx2000001530 4 Remove the connector plates. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001531 Disconnecting the axis-6 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 303 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 3 Note Disconnect the connectors. • MP6 • FB6 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001532 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001533 Disconnecting the axis-5 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 304 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 3 Note Disconnect the connectors. • MP5 • FB5 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001534 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001535 Disconnecting CP/CS cabling (if equipped) Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 For robots with CP/CS cabling Disconnect the connectors. • J1.C1 • J1.C3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001536 Continues on next page Product manual - IRB 1300 305 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 4 Note Snap loose and remove the male head of the connectors from the connector plate. xx2000001537 Separating the cable package from the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the first semicircular bracket that fixes the cable package. xx2000001748 4 Remove the second semicircular bracket from the tubular. xx2000001749 Continues on next page 306 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Removing the process hub Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws and carefully open the cover. CAUTION There is cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. xx2000001538 4 Disconnect the air hoses. xx2000001539 Continues on next page Product manual - IRB 1300 307 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 5 Note For robots with Ethernet cabling Access the connector from the process hub and disconnect the connector. • J1.C2 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001540 Tip The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Disconnecting the axis-4 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 308 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 3 Note Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001542 4 Cut the cable strap. Note The motor cablings have another strap fixed. Always cut the strap that fixes the cable package to the plate. xx2000001543 5 Disconnect the connectors. • MP4 • FB4 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001544 6 Snap loose and remove the male head of the connectors from the connector plate. xx2000001545 Separating the cable package from the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 309 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the axis-4 cable protector. xx2000001546 Disconnecting the axis-2 and -3 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate, as shown in following step. xx2000001548 Continues on next page 310 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 4 Note Cut the cable straps. xx2000001549 5 Disconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. 6 xx2000001550 Snap loose and remove the male head of the connectors from the connector plate. xx2000001551 Separating the cable package from the lower arm Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 311 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 3 Note Remove the cable bracket from the lower arm first and then from the cable package. xx2000001553 xx2100001465 4 Remove the connector plate. xx2000001554 Separating the cable package from the swing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 312 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 3 Note Remove the axis-2 cable protector. xx2000001556 4 Remove the cable brackets from the swing first and then from the cable package. xx2000001557 xx2100001466 Pulling out the cable package Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Wrap the connectors with the masking tape. Continues on next page Product manual - IRB 1300 313 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 4 Note Pull the cable package out to the swing support. xx2000001683 Removing the axis-3 timing belt Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. 4 CAUTION The upper arms, which includes housing, extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4), tubular and tilt unit weighs 17 kg. All lifting accessories used must be sized accordingly! 5 Fit a roundsling to the upper arm to support the weight (no force). Continues on next page 314 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 6 Note Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001614 7 Remove the timing belt from its groove on the motor. xx2000001615 Removing the axis-3 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. Continues on next page Product manual - IRB 1300 315 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 4 Note Remove the screws and washers. xx2000001616 5 Carefully lift out the motor. xx2000001617 Removing the lower arm support Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the lower arm support. Tip If the lower arm support is hard to loosen from the swing, use a plastic hammer to knock on the lower arm support lightly. xx2000001663 Continues on next page 316 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Separating the lower arm from the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws. WARNING This releases the upper arm from the lower arm. Make sure the weight of the upper arm is properly secured. The upper arm, including housing, extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4), tubular and tilt unit, weighs 17 kg. xx2000001664 4 Separate the lower arm from the housing. Tip If the lower arm is hard to loosen from the housing, use a plastic hammer to knock on the lower arm lightly. xx2000001665 5 Lay down the upper arm on a workbench. Make sure to support the gravity center of the upper arm. Supporting the lower arm Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 317 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Support the weight of the lower arm. Removing the axis-2 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 WARNING When separating the motor from the gearbox, there may be pressure present in the gearbox, causing lubricant to spray from the opening. Before proceeding, please read the safety information in the section Gearbox lubricants (oil or grease) on page 29. 4 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. 5 Cut the cable strap. xx2000001624 Continues on next page 318 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 6 Note Remove the cable bracket. xx2000001625 7 Access the screws and washers securing the axis2 motor from the swing support. xx2000001627 8 Remove the screws and washers. xx2000001626 9 Carefully lift out the motor. xx2000001628 Removing the swing support Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 319 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the swing support. Tip If the lower arm support is hard to loosen from the swing, use a plastic hammer to knock on the lower arm support lightly. xx2000001684 Separating the swing from the lower arm Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws. xx2000001686 Continues on next page 320 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 4 Note Separate the swing from the lower arm. Tip If the swing is hard to loosen from the lower arm, use a plastic hammer to knock on the swing lightly. xx2000001687 Removing the axis-2 sealing rings Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) Remove the sealing ring on the swing side. xx2000002516 4 Remove the sealing ring on the swing support side. xx2000001692 Continues on next page Product manual - IRB 1300 321 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Removing the axis-2 gearbox Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing gearboxes will release axes. This means the axes can fall down. Make sure axes are well supported before removing gearboxes. 4 Remove the screws. xx2000001688 5 Pull out the gearbox. xx2000001689 Continues on next page 322 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Refitting the lower arm Use these procedures to refit the lower arm. Checking mechanical stops and oil plugs Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the axis-3 mechanical stops. Replace if damaged. See Replacing the axis-3 mechanical stops on page 486. 3 Check the oil plugs. Replace if damaged. Magnetic oil plug, G 1/4": 3HAC037925-001 Tightening torque: 10 Nm xx2000001726 Refitting the axis-2 gearbox Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the O-ring. Replace if damaged. O-ring on axis-2 gear unit: 3HAC064977-004 xx2000001690 Continues on next page Product manual - IRB 1300 323 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 3 Action Note Fit guide pins to the axis-2 gearbox. Guide pin for axis-2 gearbox. Included in special toolkit 3HAC076396-001. Note Always use two guide pins together. xx2000001705 4 Refit the axis-2 gearbox, with guidance from the guide pins. xx2000001706 5 Secure with screws. Screw: M5x25 12.9 Lafre 2C2B/FC6.9 (16 pcs) Tightening torque: 8.9 Nm±3% xx2000001707 6 Remove the guide pins. xx2000001708 Continues on next page 324 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Refitting the axis-2 sealing rings Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) Check the O-ring on the swing support side. For robots with protection type Foundry Plus (option 3352-10) Check the O-rings on both swing and swing support sides. O-ring on lower arm: 3HAC061327015 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) xx2000002518 For robots with protection type Foundry Plus (option 3352-10) xx2000002517 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) Refit the sealing ring on the swing side. Sealing ring, swing side: 3HAC065675-001 Screw: M4x12 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 3.8 Nm xx2000002516 Continues on next page Product manual - IRB 1300 325 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 4 Note Refit the sealing ring on the swing support side. Sealing ring, swing support side: 3HAC065676-001 Screw: M4x12 12.9 Lafre 2C2B/FC6.9 (16 pcs) Tightening torque: 3.8 Nm xx2000001692 Check the radial sealing on the swing top (Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the swing top. Replace if damaged, as described below. xx2000002460 3 Fit the big circular plate of the axis-2 sealing as- Big circular plate of the axis-2 sembly tool to the swing (opposite side of the ra- sealing assembly tool, included in dial sealing) with three M4x12 screws. Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002461 Continues on next page 326 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 4 Note Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. 5 Fit the new sealing into the swing. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002462 xx2000002537 6 For robots with protection type Foundry Plus (option 3352-10) Place the ring of the axis-2 sealing assembly tool against the sealing. Ring of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002463 xx2000002562 Continues on next page Product manual - IRB 1300 327 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 7 Action Note Fit the small circular plate of the axis-2 sealing assembly tool and fix with three M6x75 screws. Small circular plate of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002464 xx2000002465 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Refitting the swing to the lower arm Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the O-ring. Replace if damaged. O-ring on swing: 3HAC061327-036 xx2000001750 Continues on next page 328 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 3 Action Note Refit the swing to the lower arm. M10 screws Screw: M10x25 12.9 Gleitmo 603+Geomet 500 (6 pcs) Tightening torque: 72 Nm M6 screws Screw: M6x20 12.9 Gleitmo 603+Geomet 500 (3 pcs) Tightening torque: 14 Nm xx2000001686 Check the radial sealing on the swing support (IP67, Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the swing support. Replace if damaged, as described below. xx2000002466 3 Fit the big circular plate of the axis-2 sealing as- Big circular plate of the axis-2 sembly tool to the swing support (opposite side sealing assembly tool, included in of the radial sealing) with three M4x12 screws. Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002467 Continues on next page Product manual - IRB 1300 329 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 4 Note Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. 5 Fit the new sealing into the swing support. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002468 xx2000002537 6 For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) Place the ring of the axis-2 sealing assembly tool against the sealing. Ring of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002469 xx2000002562 Continues on next page 330 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 7 Action Note Fit the small circular plate of the axis-2 sealing assembly tool and fix with three M6x75 screws. Small circular plate of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002470 xx2000002471 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Refitting the swing support Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for swing support, short: 3HAC067822-001 Gasket for swing support, long: 3HAC067823-001 xx2000002520 Continues on next page Product manual - IRB 1300 331 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 3 Note Route the cable package through the swing support. Make sure that the cable package is out from the hole near the base rear, as circled in the figure. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001747 4 Refit the swing support. Screw: M8x40 12.9 Gleitmo 603+Geomet 500 (7 pcs) Tightening torque: 36 Nm xx2000001684 5 Apply grease to the axis-2 cable protector and slip it over the cable harness. Grease: 3HAC029132-001 Plastic cable protector, axis 2: 3HAC067816-001 xx2000001567 Refitting the axis-2 motor Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 CAUTION Do not mix the axis-2 motor used for IRB 13007/1.4 and IRB 1300-12/1.4. Always carefully check the part number attached to the motor and the robot type, and refit with the right one. Axis-2 motor for IRB 1300-7/1.4: 3HAC073078-001 Axis-2 motor for IRB 1300-12/1.4: 3HAC082078-001 Continues on next page 332 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action Note 3 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 4 Check the O-ring. Replace if damaged. O-ring on motor unit: 3HAC061327037 xx2000001629 5 Apply lubricating oil to the motor that has contact- Kyodo Yushi TMO150: 3HAC032140-001 ing area with the gearbox. xx2000001701 6 Orient the motor correctly and fit it into the swing. Motor orientation: orient the motor Make sure the motor is properly fit to gearbox. according to the figure below, in regard to the encircled motor connector. xx2000001630 Continues on next page Product manual - IRB 1300 333 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 7 Action Note Refit the screws and washers. Screw: M6x20 12.9 Gleitmo 603+Geomet 500 (4 pcs) Tightening torque: 10 Nm xx2000001626 Checking the radial sealing on the lower arm (Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the lower arm. Replace if damaged, as described below. xx2000002472 Figure 5.1: 3 Fit the big circular plate of the axis-3 sealing as- Big circular plate of the axis-3 sembly tool to the lower arm (opposite side of the sealing assembly tool, included in radial sealing) with three M4x12 screws. Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002473 Continues on next page 334 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action Note 4 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. 5 Fit the new sealing into the lower arm. The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002474 xx2000002537 6 Place the ring of the axis-3 sealing assembly tool Ring of the axis-3 sealing assembly tool, included in Special toolkit for against the sealing. IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002499 xx2000002562 Continues on next page Product manual - IRB 1300 335 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 7 Action Note Fit the small circular plate of the axis-3 sealing assembly tool against the sealing and fix with three M6x75 screws. Small circular plate of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002475 xx2000002476 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Refitting the lower arm to the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the lower arm to the housing. Screw: M4x16 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Tightening torque: 4.5 Nm±3% xx2000001664 Continues on next page 336 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Checking the radial sealing on the lower arm support (IP67, Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the lower arm support. Replace if damaged, as described below. xx2000002477 3 Fit the big circular plate of the axis-3 sealing assembly tool to the lower arm support (opposite side of the radial sealing) with three M4x12 screws. Big circular plate of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002478 4 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. Continues on next page Product manual - IRB 1300 337 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 5 Note Fit the new sealing into the lower arm support. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002479 xx2000002537 6 For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) Place the ring of the axis-3 sealing assembly tool against the sealing. Ring of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002480 xx2000002562 Continues on next page 338 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 7 Action Note Fit the small circular plate of the axis-3 sealing assembly tool and fix with three M6x75 screws. Small circular plate of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002481 xx2000002482 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Refitting the lower arm support Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for lower arm support: 3HAC067826-001 xx2000002521 Continues on next page Product manual - IRB 1300 339 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 3 Action Note Refit the lower arm support. Screw: M8x40 12.9 Gleitmo 603+Geomet 500 (7 pcs) Tightening torque: 39 Nm±3% xx2000001663 Refitting the axis-3 motor Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 CAUTION Do not mix the axis-3 motor used for IRB 13007/1.4 and IRB 1300-12/1.4. Always carefully check the part number attached to the motor and the robot type, and refit with the right one. 3 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 4 Valid for IRB 1300-12/1.4 Check the resolver cover. Replace if damaged. Axis-3 motor for IRB 1300-7/1.4: 3HAC073086-001 Axis-3 motor for IRB 1300-12/1.4: 3HAC082079-001 Resolver cover on motor (IRB 1300-12/1.4): 3HAC060261-001 xx2100002770 Continues on next page 340 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 5 Note Orient the motor correctly and fit it into the lower Motor orientation: orient the motor arm. according to the figure below, in regard to the encircled motor connector. xx2000001618 6 Refit the screws and washers. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Note Do not tighten the screws yet. xx2000001616 Refitting the axis-3 timing belt Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx2000001615 3 Move the motor to achieve proper belt tension. 4 Use a sonic tension meter to measure the timing belt tension. If the timing belt tension does not meet the requirement, loosen the motor screws and readjust. Used belt: 73.4-78.5 Hz New belt: 87.8-92.1 Hz Continues on next page Product manual - IRB 1300 341 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 5 Action Note Secure the motor with the screws. Tightening torque: 3.3 Nm xx2000001614 6 Release the support to the upper arm. Securing the cable package in the swing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Route the cable package up into the lower arm. Make sure that the the air hoses are facing outside in the axis-2 cable protector, see the figure as a guidance for the cable twisting way. xx2000001746 Continues on next page 342 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 3 Action Note Refit the cable brackets. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each bracket on cable package and 2 pcs on swing) Tightening torque: 2.6 Nm xx2100001466 xx2000001557 4 Refit the axis-2 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001556 Routing the cable package in the lower arm Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 343 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 2 Action Note Refit the connector plate to the cable package. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001554 3 Check the axis-3 cable protector. Replace if damaged. Grease: 3HAC029132-001 Plastic cable protector, axis 3: 3HAC064693-001 Note If replaced, apply grease to the axis-3 cable protector before refitting. xx2000001568 Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 2.6 Nm xx2000001552 4 Route the cable package through the lower arm support and up into the housing. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001569 Continues on next page 344 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Reconnecting the axis-2 and -3 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001551 3 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001549 4 Reconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip See the number markings on the connectors for help to find the corresponding connector. 5 Refit the connector plate to the lower arm. xx2000001550 Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001548 Continues on next page Product manual - IRB 1300 345 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Securing the cable package in the lower arm Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the cable bracket. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs on the cable package and 2 pcs on lower arm) Tightening torque: 2.6 Nm xx2100001465 xx2000001553 Routing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Slip the axis-4 cable protector over the cable package. Plastic cable protector, axis 4: 3HAC064694-001: xx2000001570 Continues on next page 346 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 3 Note Insert the cable package through the hollow tube of the axis-4 gearbox, into the extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4) and into the tubular. Make sure that: • the air hoses are facing the axis-3 gearbox side in the hollow tube of axis-4 gearbox. CAUTION xx2000001571 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Securing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the axis-4 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001546 Reconnecting the axis-4 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001545 Continues on next page Product manual - IRB 1300 347 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 3 Note Reconnect the connectors. • FB4 • MP4 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001544 4 Route and secure the cabling with a cable strap. Note The motor cablings have another strap fixed. Pay attention to the location where the new strap to be fixed, see the figure as a guidance. CAUTION xx2000001543 Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the connector plate. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001542 Routing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 348 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 2 Note Refit the second semicircular bracket to the tubu- Screw: M4x8 12.9 Lafre lar. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001749 3 Route the cablings. • Leave the CP/CS connectors and motor connectors out from the tubular support, and Ethernet connectors and air hoses out from the process hub. • The air hoses are facing upside in the semicircular bracket. Reconnecting the air hoses and Ethernet cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Reconnect the air hoses. Note See the number markings on the air hoses for help to find the corresponding air hoses. xx2000001539 3 For robots with Ethernet cabling Access the connector from the process hub and reconnect the connector. • J1.C2 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001540 Continues on next page Product manual - IRB 1300 349 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Reconnecting the CP/CS cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the connectors to the connector plate. xx2000001537 3 For robots with CP/CS cabling Reconnect the connectors. • J1.C1 • J1.C3 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001536 Reconnecting the axis-5 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001535 Continues on next page 350 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 3 Note Reconnect the connectors. • FB5 • MP5 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001534 Reconnecting the axis-6 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001533 3 Reconnect the connectors. • FB6 • MP6 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001532 Refitting the process hub Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 351 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued 2 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for process hub: 3HAC070887-001 xx2000002512 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolts. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002513 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the process hub. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001538 Securing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 352 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 2 Note Refit the first semicircular bracket to fix the cable Screw: M4x12 12.9 Lafre package. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001748 3 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each plate) Tightening torque: 1.3 Nm xx2000001531 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001530 Refitting the covers Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 353 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 2 Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gaskets. • Gasket for tubular support cover (A) • Gasket for housing cover (B) • Gasket for lower arm covers (C) • Gasket for swing covers (D) Replace if damaged. xx2000002501 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm covers (C) • Swing covers (D) Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001724 Jogging the robot to oil filling position Action 1 Note Turn on the electric power to the robot. If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to Supplying power to connector R1.MP on page 66. Continues on next page 354 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 2 Note Jog the robot to the specified position: • Axis 1: 0° • Axis 2: -67.5 • Axis 3: 0° • Axis 4: 0° • Axis 5: 0° • Axis 6: No significance. xx2000001519 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Refilling oil to axis-2 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. Continues on next page Product manual - IRB 1300 355 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action 3 Note Open the upper oil plug. Note The lower oil plug has to be closed; otherwise, the oil may leak before required oil amount is filled. xx2000001518 A Oil plug, opened B Oil plug, closed 4 WARNING Overfilling of gearbox lubricant can lead to internal over-pressure inside the gearbox which in turn may: • damage seals and gaskets • completely press out seals and gaskets • prevent the robot from moving freely. 5 Refill the gearbox with oil. Note Type of oil and total amount is detailed in Technical reference manual - Lubrication in gearboxes. The amount of oil to be filled depends on the amount previously being drained. CAUTION Oil filling must be slow to make sure air venting is fluent. 6 Inspect the oil level by measuring the level at the upper oil plug hole. Required oil level: within the range of 64 mm to 69 mm below the edge of the oil plug hole. CAUTION The oil level sinks when the oil fills all cavities in the gearbox. Wait until the oil stops sinking, before measuring the oil level. xx2000001580 7 Refit the oil plug. Tightening torque: 10 Nm Continues on next page 356 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action Note 8 DANGER Make sure all safety requirements are met when performing the first test run. Jogging the robot to zero position Action Note 1 Turn on the electric power to the robot. If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to Supplying power to connector R1.MP on page 66. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. Continues on next page Product manual - IRB 1300 357 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.1 Replacing the lower arm Continued Action Note 3 DANGER Make sure all safety requirements are met when performing the first test run. 358 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit 5.5.2 Replacing the housing and extender unit Locations of the housing and extender unit The housing is located as shown in the figure. xx2000001476 Continues on next page Product manual - IRB 1300 359 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued The extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4) is located as shown in the figure. xx2000001477 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Housing 3HAC073079-001 Housing, IP67 3HAC077801-001 Used with protection class IP67. Housing, Clean Room 3HAC077814-001 Used with protection type Clean Room. Housing, Foundry Plus 3HAC077848-001 Used with protection type Foundry Plus. Extender unit 3HAC073085-001 Used for IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Extender unit, Clean Room 3HAC077818-001 Used for IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Continues on next page 360 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Spare part Article number Note Extender unit, Foundry Plus 3HAC077852-001 Used for IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Foundry Plus. Lower arm support 3HAC073076-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm support, Clean Room 3HAC077813-001 Used with protection type Clean Room. Gear unit, axis 4 3HAC073084-001 O-ring on circular spline side, axis 3HAC061327-021 4 Not used with protection class IP40. Replace if damaged. O-ring on flexible spline side, axis 3HAC061327-017 4 Not used with protection class IP40. Replace if damaged. Motor unit, axis 4 3HAC073087-001 Timing belt, axis 4 3HAC065806-001 Mechanical stop, axis 4, flange 3HAC065805-001 Replace if damaged. Mechanical stop, axis 4, slider 3HAC065804-001 Replace if damaged. Process hub, basic 3HAC073306-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Plastic cable protector, axis 3 3HAC064693-001 Plastic cable protector, axis 4 3HAC064694-001 Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page Product manual - IRB 1300 361 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Spare part Article number Note Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm support 3HAC067826-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Radial sealing on lower arm 3HAC070148-005 Not used with protection class IP40. Replace if damaged. Radial sealing on housing 3HAC070148-006 Used with protection types Clean Room and Foundry Plus. Replace if damaged. O-ring on tubular 3HAC061327-018 Not used with protection class IP40. Replace if damaged. Plug screw 3HAC078352-001 Not used with protection type Clean Room. Replace if damaged. Plug screw, Clean Room 3HAC078351-001 Used with protection type Clean Room. Replace if damaged. Continues on next page 362 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Spare part Article number Note Rubber sealing washer 3HAC075325-001 Used with protection type Clean Room. Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Sonic tension meter - Used for measuring the timing belt tension. Tension adjustment tool for axis-4 timing belt Included in special toolkit 3HAC076396-001. Dynamometer - Used for measuring the timing belt tension. Special toolkit for IP67/Clean Room/Foundry Plus robots 3HAC078203-001 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. Consumable Article number Note Cable straps - Grease 3HAC029132-001 Required consumables FM 222 Removing the housing Use these procedures to remove the housing. Preparations before removing the housing Action 1 Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1300 363 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 2 Note Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Removing the covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 364 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 3 Note Remove the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm covers (C) xx2000001661 Loosening the cables in the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Cut the cable straps. xx2000001530 4 Remove the connector plates. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001531 Continues on next page Product manual - IRB 1300 365 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Disconnecting the axis-6 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP6 • FB6 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001532 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001533 Disconnecting the axis-5 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 366 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP5 • FB5 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001534 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001535 Disconnecting CP/CS cabling (if equipped) Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 367 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 3 Note For robots with CP/CS cabling Disconnect the connectors. • J1.C1 • J1.C3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001536 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001537 Separating the cable package from the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the first semicircular bracket that fixes the cable package. xx2000001748 Continues on next page 368 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 4 Note Remove the second semicircular bracket from the tubular. xx2000001749 Removing the process hub Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws and carefully open the cover. CAUTION There is cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. xx2000001538 4 Disconnect the air hoses. xx2000001539 Continues on next page Product manual - IRB 1300 369 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 5 Note For robots with Ethernet cabling Access the connector from the process hub and disconnect the connector. • J1.C2 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001540 Tip The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Disconnecting the axis-4 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 370 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 3 Note Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001542 4 Cut the cable strap. Note The motor cablings have another strap fixed. Always cut the strap that fixes the cable package to the plate. xx2000001543 5 Disconnect the connectors. • MP4 • FB4 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001544 6 Snap loose and remove the male head of the connectors from the connector plate. xx2000001545 Separating the cable package from the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 371 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the axis-4 cable protector. xx2000001546 Disconnecting the axis-2 and -3 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate, as shown in following step. xx2000001548 Continues on next page 372 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 4 Note Cut the cable straps. xx2000001549 5 Disconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. 6 xx2000001550 Snap loose and remove the male head of the connectors from the connector plate. xx2000001551 Pulling out the cable package Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 373 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 3 Note Remove the cable bracket from the lower arm first and then from the cable package. xx2000001553 xx2100001465 4 Wrap the connectors with the masking tape. 5 Pull the cable package out to the lower arm support. Note During the routing, make sure the axis-2 motor cablings are kept visible and accessible from the lower arm support side. xx2000001662 Removing the axis-4 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 374 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 3 Note CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. 4 Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001604 5 Remove the timing belt from its groove on the motor. 6 Remove the screws and washers. xx2000001605 7 Carefully lift out the motor. xx2000001669 8 Remove the timing belt. xx2000001670 Continues on next page Product manual - IRB 1300 375 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Removing the lower arm support Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the lower arm support. Tip If the lower arm support is hard to loosen from the swing, use a plastic hammer to knock on the lower arm support lightly. xx2000001663 Removing the axis-3 timing belt Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. Continues on next page 376 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action Note 4 CAUTION The upper arms, which includes housing, extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4), tubular and tilt unit weighs 17 kg. All lifting accessories used must be sized accordingly! 5 Fit a roundsling to the upper arm to support the weight (no force). 6 Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001614 7 Remove the timing belt from its groove on the motor. xx2000001615 Separating the lower arm from the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 377 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 3 Note Remove the screws. WARNING This releases the upper arm from the lower arm. Make sure the weight of the upper arm is properly secured. The upper arm, including housing, extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4), tubular and tilt unit, weighs 17 kg. xx2000001664 4 Separate the lower arm from the housing. Tip If the lower arm is hard to loosen from the housing, use a plastic hammer to knock on the lower arm lightly. xx2000001665 5 Lay down the upper arm on a workbench. Make sure to support the gravity center of the upper arm. Removing the axis-3 gearbox Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing gearboxes will release axes. This means the axes can fall down. Make sure axes are well supported before removing gearboxes. Continues on next page 378 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 4 Note Remove the screws. xx2000001666 5 Pull out the gearbox. xx2000001667 Separating the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Support the weight of the extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4), tubular and tilt unit, and remove the screws. xx2000001729 Continues on next page Product manual - IRB 1300 379 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 4 Note Valid for IRB 1300-11/0.9 and IRB 1300-10/1.15 Separate the tubular from the housing. xx2000001728 5 Valid for IRB 1300-7/1.4 and IRB 1300-12/1.4 Separate the extender unit from the housing. xx2000001727 Removing the axis-4 mechanical stop slider Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Access the axis-4 mechanical stop slider from the housing. Put it aside for later refitting. xx2000001732 Continues on next page 380 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Removing the extender unit Note Only IRB 1300-7/1.4 and IRB 1300-12/1.4 have an extender unit, connecting the housing and tubular. Use these procedures to continuously remove the extender unit after removing the housing. Removing the axis-4 mechanical stop flange Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the axis-4 mechanical stop flange. CAUTION The axis-4 mechanical stop slider is accessible from the housing. Put it aside for later refitting. xx2000001673 xx2000001674 Continues on next page Product manual - IRB 1300 381 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Removing the axis-4 gearbox Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing gearboxes will release axes. This means the axes can fall down. Make sure axes are well supported before removing gearboxes. 4 Remove the screws. xx2000001675 5 Pull out the gearbox. xx2000001676 Separating the extender unit Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 382 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Separate the extender unit from the tubular. xx2000001730 Refitting the extender unit Note Only IRB 1300-7/1.4 and IRB 1300-12/1.4 have an extender unit, connecting the housing and tubular. Use these procedures to refit the extender unit before refitting the housing. Refitting the extender unit Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the O-ring. Replace if damaged. O-ring on tubular: 3HAC061327018 xx2000002519 Continues on next page Product manual - IRB 1300 383 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued 3 Action Note Refit the extender unit. Screw: M4x25 12.9 Lafre 2C2B/FC6.9 (12 pcs) Tightening torque: 3.8 Nm xx2000001730 4 Make sure that the notches on the extender unit and tubular are aligned. xx2000001731 Refitting the axis-4 gearbox Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the o-rings. Replace if damaged. O-ring on circular spline side, axis 4: 3HAC061327-021 O-ring on flexible spline side, axis 4: 3HAC061327-017 xx2000002525 Continues on next page 384 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 3 Note Refit the axis-4 gearbox. xx2000001676 4 Make sure that the screws on the gearbox are properly fitted into the notches on the extender unit. xx2000001720 xx2000001679 5 Secure with screws. Screw: M3x35 12.9 Lafre 2C2B/FC6.9 (12 pcs) Tightening torque: 1.9 Nm xx2000001675 Refitting the axis-4 mechanical stop flange Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 385 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 2 Note Refit the axis-4 mechanical stop flange to the gearbox. xx2000001673 3 Make sure that : • the block on the mechanical stop flange is towards the upper side (process hub side). • the notches on the extender unit and the mechanical stop flange are aligned. xx2000001678 xx2000001677 Refitting the housing Use these procedures to refit the housing. Check the radial sealing on the housing (IP67, Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the housing. Replace if damaged, as described below. xx2000002483 Continues on next page 386 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued 3 Action Note Fit the lug plate of the axis-4 sealing assembly tool into the housing with three M4x10 screws. Lug plate of the axis-4 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). Note Pay attention to the location of the lugs. xx2000002484 xx2000002485 4 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. 5 Fit the new sealing into the housing. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002486 xx2000002537 Continues on next page Product manual - IRB 1300 387 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 6 Note Fit the circular plate of the axis-4 sealing assembly Circular plate of the axis-4 sealing tool against the sealing and fix with three M6x85 assembly tool, included in Special screws. toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002487 xx2000002488 7 Screw the screws, little by little and evenly, to press the sealing into place. 8 Remove the assembly tool. 9 Check that the sealing is undamaged and properly fitted. Refitting the axis-4 mechanical stop slider Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Place the axis-4 mechanical stop slider in the housing. xx2000001732 Continues on next page 388 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Refitting the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option O-ring on tubular: 3HAC0613273350-670) 018 For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Valid for IRB 1300-11/0.9 and IRB 1300-10/1.15 Check the O-ring. Replace if damaged. xx2000002519 3 Valid for IRB 1300-11/0.9 and IRB 1300-10/1.15 Refit the tubular to the housing. xx2000001728 4 Valid for IRB 1300-7/1.4 and IRB 1300-12/1.4 Refit the extender unit to the housing. xx2000001727 5 Refit the screws. Screw: M4x12 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (14 pcs) Tightening torque: 3.3 Nm xx2000001729 Continues on next page Product manual - IRB 1300 389 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Refitting the axis-3 gearbox Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the O-ring. Replace if damaged. O-ring on circular spline side, axis 3: 3HAC061327-016 xx2000002524 3 Refit the axis-3 gearbox. xx2000001667 4 Secure with screws. Screw: M4x35 12.9 Lafre 2C2B/FC6.9 (12 pcs) Tightening torque: 4.2 Nm±3% xx2000001666 Checking the radial sealing on the lower arm (Foundry Plus) Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 390 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 2 Note Check the radial sealing on the lower arm. Replace if damaged, as described below. xx2000002472 Figure 5.2: 3 Fit the big circular plate of the axis-3 sealing as- Big circular plate of the axis-3 sembly tool to the lower arm (opposite side of the sealing assembly tool, included in radial sealing) with three M4x12 screws. Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002473 4 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. 5 Fit the new sealing into the lower arm. The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002474 xx2000002537 Continues on next page Product manual - IRB 1300 391 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 6 Note Place the ring of the axis-3 sealing assembly tool Ring of the axis-3 sealing assembly against the sealing. tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002499 xx2000002562 7 Fit the small circular plate of the axis-3 sealing assembly tool against the sealing and fix with three M6x75 screws. Small circular plate of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002475 xx2000002476 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Refitting the lower arm to the housing Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 392 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued 2 Action Note Refit the lower arm to the housing. Screw: M4x16 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Tightening torque: 4.5 Nm±3% xx2000001664 Checking the radial sealing on the lower arm support (IP67, Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the lower arm support. Replace if damaged, as described below. xx2000002477 3 Fit the big circular plate of the axis-3 sealing assembly tool to the lower arm support (opposite side of the radial sealing) with three M4x12 screws. Big circular plate of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002478 Continues on next page Product manual - IRB 1300 393 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 4 Note Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. 5 Fit the new sealing into the lower arm support. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002479 xx2000002537 6 For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) Place the ring of the axis-3 sealing assembly tool against the sealing. Ring of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002480 xx2000002562 Continues on next page 394 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued 7 Action Note Fit the small circular plate of the axis-3 sealing assembly tool and fix with three M6x75 screws. Small circular plate of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002481 xx2000002482 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Refitting the lower arm support Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for lower arm support: 3HAC067826-001 xx2000002521 Continues on next page Product manual - IRB 1300 395 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued 3 Action Note Refit the lower arm support. Screw: M8x40 12.9 Gleitmo 603+Geomet 500 (7 pcs) Tightening torque: 39 Nm±3% xx2000001663 Refitting the axis-3 timing belt Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx2000001615 3 Move the motor to achieve proper belt tension. 4 Use a sonic tension meter to measure the timing belt tension. If the timing belt tension does not meet the requirement, loosen the motor screws and readjust. 5 Secure the motor with the screws. Used belt: 73.4-78.5 Hz New belt: 87.8-92.1 Hz Tightening torque: 3.3 Nm xx2000001614 6 Release the support to the upper arm. Continues on next page 396 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Refitting the axis-4 motor Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 3 Install the timing belt to the gearbox pulley and verify that the belt runs correctly in the grooves of the pulley. xx2000001670 4 Orient the motor correctly and fit it into the hous- Motor orientation: orient the motor ing. according to the figure below, in regard to the encircled motor connector. Note Make sure the motor flange does not press on the timing belt. xx2000001607 5 Refit the motor and verify that the timing belt runs correctly in the groove of the motor pulley. xx2000001680 Continues on next page Product manual - IRB 1300 397 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued 6 Action Note Refit the screws and washers. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (3 pcs) Note Do not tighten the screws yet. xx2000001605 Adjusting the axis-4 timing belt tension Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Remove the screw below the housing. xx2000001609 3 Fit the tension adjustment tool for axis-4 timing belt to the screw hole. Tension adjustment tool for axis-4 timing belt. Included in special toolkit 3HAC076396-001. xx2000001610 Continues on next page 398 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 4 Note Use a handheld dynamometer hooking to the tool. xx2000001611 5 Pull the dynamometer to make the tension falling Used belt: 16.7-19.1 N in the allowed force range. New belt:23.9-26.2 N Note Pay attention to the force application direction. xx2000001612 6 Secure the motor with the screws. Tightening torque: 3.3 Nm±3% xx2000001604 Continues on next page Product manual - IRB 1300 399 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued 7 Action Note Remove the tool and refit the plug screw. For robots with protection type Clean Room (option 3351-4) Refit the plug screw with the rubber washer. Tightening torque: 3 Nm For robots NOT with protection type Clean Room Plug screw: 3HAC078352-001 xx2000001609 For robots with protection type Clean Room (option 3351-4) Plug screw, Clean Room: 3HAC078351-001 Rubber sealing washer: 3HAC075325-001 xx2000002496 Routing the cable package in the lower arm Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the connector plate to the cable package. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001554 Continues on next page 400 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued 3 Action Note Check the axis-3 cable protector. Replace if damaged. Grease: 3HAC029132-001 Plastic cable protector, axis 3: 3HAC064693-001 Note If replaced, apply grease to the axis-3 cable protector before refitting. xx2000001568 Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 2.6 Nm xx2000001552 4 Route the cable package through the lower arm support and up into the housing. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001569 Reconnecting the axis-2 and -3 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001551 Continues on next page Product manual - IRB 1300 401 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 3 Note Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001549 4 Reconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip See the number markings on the connectors for help to find the corresponding connector. 5 Refit the connector plate to the lower arm. xx2000001550 Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001548 Securing the cable package in the lower arm Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 402 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued 2 Action Note Refit the cable bracket. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs on the cable package and 2 pcs on lower arm) Tightening torque: 2.6 Nm xx2100001465 xx2000001553 Routing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Slip the axis-4 cable protector over the cable package. Plastic cable protector, axis 4: 3HAC064694-001: xx2000001570 Continues on next page Product manual - IRB 1300 403 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 3 Note Insert the cable package through the hollow tube of the axis-4 gearbox, into the extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4) and into the tubular. Make sure that: • the air hoses are facing the axis-3 gearbox side in the hollow tube of axis-4 gearbox. CAUTION xx2000001571 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Securing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the axis-4 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001546 Reconnecting the axis-4 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001545 Continues on next page 404 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 3 Note Reconnect the connectors. • FB4 • MP4 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001544 4 Route and secure the cabling with a cable strap. Note The motor cablings have another strap fixed. Pay attention to the location where the new strap to be fixed, see the figure as a guidance. CAUTION xx2000001543 Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the connector plate. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001542 Routing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 405 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 2 Note Refit the second semicircular bracket to the tubu- Screw: M4x8 12.9 Lafre lar. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001749 3 Route the cablings. • Leave the CP/CS connectors and motor connectors out from the tubular support, and Ethernet connectors and air hoses out from the process hub. • The air hoses are facing upside in the semicircular bracket. Reconnecting the air hoses and Ethernet cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Reconnect the air hoses. Note See the number markings on the air hoses for help to find the corresponding air hoses. xx2000001539 3 For robots with Ethernet cabling Access the connector from the process hub and reconnect the connector. • J1.C2 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001540 Continues on next page 406 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Reconnecting the CP/CS cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the connectors to the connector plate. xx2000001537 3 For robots with CP/CS cabling Reconnect the connectors. • J1.C1 • J1.C3 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001536 Reconnecting the axis-5 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001535 Continues on next page Product manual - IRB 1300 407 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 3 Note Reconnect the connectors. • FB5 • MP5 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001534 Reconnecting the axis-6 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001533 3 Reconnect the connectors. • FB6 • MP6 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001532 Refitting the process hub Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 408 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued 2 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for process hub: 3HAC070887-001 xx2000002512 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolts. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002513 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the process hub. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001538 Securing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 409 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 2 Note Refit the first semicircular bracket to fix the cable Screw: M4x12 12.9 Lafre package. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001748 3 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each plate) Tightening torque: 1.3 Nm xx2000001531 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001530 Refitting the covers Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 410 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.2 Replacing the housing and extender unit Continued Action 2 Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gaskets. • Gasket for tubular support cover (A) • Gasket for housing cover (B) • Gasket for lower arm covers (C) Replace if damaged. xx2000002502 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm covers (C) Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001661 Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. 3 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1300 411 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit 5.5.3 Replacing the tubular and tilt unit Locations of the tubular and tilt unit The tubular is located as shown in the figure. xx2000001478 Continues on next page 412 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued The tilt unit is located as shown in the figure. xx2000001479 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Tilt unit 3HAC073083-001 Tilt unit, IP67 3HAC077804-001 Used with protection class IP67. Tilt unit, Clean Room 3HAC077817-001 Used with protection type Clean Room. Tilt unit, Foundry Plus 3HAC077851-001 Used with protection type Foundry Plus. Tubular 3HAC073081-001 Used with protection classes IP40 and IP67. Tubular, Clean Room 3HAC077815-001 Used with protection type Clean Room. Tubular, Foundry Plus 3HAC077849-001 Used with protection type Foundry Plus. Tubular support 3HAC073082-001 Tubular support, IP67 3HAC077803-001 Used with protection class IP67. Continues on next page Product manual - IRB 1300 413 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Spare part Article number Note Tubular support, Clean Room 3HAC077816-001 Used with protection type Clean Room. Tubular support, Foundry Plus 3HAC077850-001 Used with protection type Foundry Plus. Gear unit, axis 4 3HAC073084-001 Motor unit, axis 4 3HAC073087-001 Motor unit, axis 5 and axis 6 3HAC073088-001 Timing belt, axis 4 3HAC065806-001 Timing belt, axis 5 3HAC065794-001 Timing belt, axis 6 3HAC065788-001 Mechanical stop, axis 4, flange 3HAC065805-001 Replace if damaged. Mechanical stop, axis 4, slider 3HAC065804-001 Replace if damaged. Process hub, basic 3HAC073306-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Plastic cable protector, axis 3 3HAC064693-001 Plastic cable protector, axis 4 3HAC064694-001 Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Continues on next page 414 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Spare part Article number Note Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Radial sealing on lower arm 3HAC070148-005 Not used with protection class IP40. Replace if damaged. Radial sealing on housing 3HAC070148-006 Used with protection types Clean Room and Foundry Plus. Replace if damaged. O-ring on tubular 3HAC061327-018 Not used with protection class IP40. Replace if damaged. Plug screw 3HAC078352-001 Not used with protection type Clean Room. Replace if damaged. Plug screw, Clean Room 3HAC078351-001 Used with protection type Clean Room. Replace if damaged. Rubber sealing washer 3HAC075325-001 Used with protection type Clean Room. Replace if damaged. M2 variseal sealing 3HAC044641-008 Used with protection type Foundry Plus. Sealing with dust lip 3HAC070148-010 Used with protection type Foundry Plus. Inner ring cover on tilt unit 3HAC075327-001 Used with protection type Foundry Plus. Outer ring cover on tilt unit 3HAC075326-001 Used with protection type Foundry Plus. Gasket for tool mounting 3HAC077475-001 Used with protection type Foundry Plus. Continues on next page Product manual - IRB 1300 415 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Required tools and equipment Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Sonic tension meter - Used for measuring the timing belt tension. Tension adjustment tool for axis-4 timing belt Included in special toolkit 3HAC076396-001. Dynamometer - Used for measuring the timing belt tension. Special toolkit for IP67/Clean Room/Foundry Plus robots 3HAC078203-001 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. Consumable Article number Note Cable straps - Grease 3HAC029132-001 FM 222 Flange sealant - Loctite 574 Cleaning agent - Isopropanol Required consumables Removing the tubular and tilt unit (IRB 1300-11/0.9 and IRB 1300-10/1.15) Use these procedures to remove the tubular and tilt unit for IRB 1300-11/0.9 and IRB 1300-10/1.15. Preparations before removing the tubular and tilt unit Action 1 Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page 416 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 2 Note Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Removing the covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 417 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note Remove the covers. • Tubular covers (A) • Housing cover (B) • Lower arm support cover (C) xx2000001733 Loosening the cables in the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Cut the cable straps. xx2000001530 4 Remove the connector plates. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001531 Continues on next page 418 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Disconnecting the axis-6 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP6 • FB6 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001532 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001533 Disconnecting the axis-5 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 419 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP5 • FB5 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001534 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001535 Disconnecting CP/CS cabling (if equipped) Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 420 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note For robots with CP/CS cabling Disconnect the connectors. • J1.C1 • J1.C3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001536 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001537 Separating the cable package from the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the first semicircular bracket that fixes the cable package. xx2000001748 Continues on next page Product manual - IRB 1300 421 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Remove the second semicircular bracket from the tubular. xx2000001749 Removing the process hub Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws and carefully open the cover. CAUTION There is cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. xx2000001538 4 Disconnect the air hoses. xx2000001539 Continues on next page 422 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 5 Note For robots with Ethernet cabling Access the connector from the process hub and disconnect the connector. • J1.C2 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001540 Tip The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Removing the axis-5 timing belt Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. Continues on next page Product manual - IRB 1300 423 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001594 5 Remove the timing belt from its groove on the motor. xx2000001595 Removing the axis-5 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. Continues on next page 424 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Remove the screws and washers. xx2000001596 5 Carefully lift out the motor. xx2000001597 Removing the axis-6 timing belt Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. Continues on next page Product manual - IRB 1300 425 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001599 5 Remove the timing belt from its groove on the motor. xx2000001600 Removing the axis-6 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. Continues on next page 426 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Remove the screws and washers. xx2000001601 5 Carefully lift out the motor. xx2000001602 Disconnecting the axis-4 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001542 Continues on next page Product manual - IRB 1300 427 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Cut the cable strap. Note The motor cablings have another strap fixed. Always cut the strap that fixes the cable package to the plate. xx2000001543 5 Disconnect the connectors. • MP4 • FB4 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001544 6 Snap loose and remove the male head of the connectors from the connector plate. xx2000001545 Separating the cable package from the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 428 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note Remove the axis-4 cable protector. xx2000001546 Pulling out the cable package Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Wrap the connectors with the masking tape. 4 Pull the cable package out to the lower arm support. xx2000001662 Removing the axis-4 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 429 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. 4 Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001604 5 Remove the timing belt from its groove on the motor. 6 Remove the screws and washers. xx2000001605 7 Carefully lift out the motor. xx2000001669 Continues on next page 430 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 8 Note Remove the timing belt. xx2000001670 Separating the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Support the weight of the tubular and tilt unit, and remove the screws. xx2000001729 4 Separate the tubular from the housing. xx2000001734 Continues on next page Product manual - IRB 1300 431 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Removing the axis-4 mechanical stop flange Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the axis-4 mechanical stop flange. CAUTION The axis-4 mechanical stop slider is accessible from the housing. Put it aside for later refitting. xx2000001735 xx2000001674 Removing the axis-4 gearbox Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 432 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing gearboxes will release axes. This means the axes can fall down. Make sure axes are well supported before removing gearboxes. 4 Remove the screws. xx2000001736 5 Pull out the gearbox. xx2000001737 Separating the tubular support Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 433 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note Remove the tubular support. Tip If the tubular support is hard to loosen from the tubular, use a plastic hammer to knock on the tubular support lightly. xx2000001740 Separating the tilt unit Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the tilt unit. xx2000001741 Removing the tubular and tilt unit (IRB 1300-7/1.4 and IRB 1300-12/1.4) Use these procedures to remove the tubular and tilt unit for IRB 1300-7/1.4 and IRB 1300-12/1.4. Preparations before removing the tubular and tilt unit Action 1 Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page 434 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 2 Note Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Removing the tubular covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 435 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note Remove the tubular covers. xx2000001593 Loosening the cables in the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Cut the cable straps. xx2000001530 4 Remove the connector plates. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001531 Continues on next page 436 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Disconnecting the axis-6 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP6 • FB6 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001532 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001533 Disconnecting the axis-5 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 437 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP5 • FB5 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001534 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001535 Disconnecting CP/CS cabling (if equipped) Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 438 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note For robots with CP/CS cabling Disconnect the connectors. • J1.C1 • J1.C3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001536 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001537 Separating the cable package from the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the first semicircular bracket that fixes the cable package. xx2000001748 Continues on next page Product manual - IRB 1300 439 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Remove the second semicircular bracket from the tubular. xx2000001749 Removing the process hub Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws and carefully open the cover. CAUTION There is cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. xx2000001538 4 Disconnect the air hoses. xx2000001539 Continues on next page 440 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 5 Note For robots with Ethernet cabling Access the connector from the process hub and disconnect the connector. • J1.C2 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001540 Tip The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Removing the axis-5 timing belt Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. Continues on next page Product manual - IRB 1300 441 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001594 5 Remove the timing belt from its groove on the motor. xx2000001595 Removing the axis-5 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. Continues on next page 442 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Remove the screws and washers. xx2000001596 5 Carefully lift out the motor. xx2000001597 Removing the axis-6 timing belt Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. Continues on next page Product manual - IRB 1300 443 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001599 5 Remove the timing belt from its groove on the motor. xx2000001600 Removing the axis-6 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. Continues on next page 444 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Remove the screws and washers. xx2000001601 5 Carefully lift out the motor. xx2000001602 Separating the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the tubular and tilt unit from the extender unit. xx2000001739 Continues on next page Product manual - IRB 1300 445 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Separating the tubular support Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the tubular support. Tip If the tubular support is hard to loosen from the tubular, use a plastic hammer to knock on the tubular support lightly. xx2000001740 Separating the tilt unit Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 446 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note Remove the tilt unit. xx2000001741 Refitting the tubular and tilt unit (IRB 1300-11/0.9 and IRB 1300-10/1.15) Use these procedures to refit the tubular and tilt unit for IRB 1300-11/0.9 and IRB 1300-10/1.15. Checking the sealing set on the tilt unit (Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the sealing set on the tilt unit. The sealing set includes an inner ring cover (A), a radial sealing (B), an outer ring cover (C) and a gasket (D). Replace the damaged part as described below: • If the inner ring cover is damaged, proceed to 3. • If the radial sealing is damaged, proceed to 4. • If the outer ring cover is damaged, proceed to 5. • If the gasket is damaged, proceed to 6. 3 xx2000002489 Remove the old inner ring cover and fit the new one with two M3x8 countersunk screws. xx2000002490 Continues on next page Product manual - IRB 1300 447 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Remove the old radial sealing and fit the new one as described below. The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002491 xx2000002537 1. Apply a little grease to the sealing lip when re- Grease: 3HAC029132-001 placing the radial sealing and wipe clean after the replacement. 2. Fit the small cap of the axis-6 sealing assembly Small cap of the axis-6 sealing assembly tool, included in Special tool against inner ring cover and fix with two toolkit for IP67/Clean M6x16 screws. Room/Foundry Plus robots (3HAC078203-001). xx2000002492 3. Fit the big cap of the axis-6 sealing assembly Big cap of the axis-6 sealing astool against the sealing and fix with two M6x25 sembly tool, included in Special toolkit for IP67/Clean screws. Room/Foundry Plus robots (3HAC078203-001). xx2000002493 4. Screw the screws, little by little and evenly, to press the sealing into place. Continues on next page 448 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action Note 5. Remove the assembly tool. 6. Check that the sealing is undamaged and properly fitted. 5 Remove the inner ring cover and radial sealing first, then, remove the outer ring cover and fit the new one. Remember to refit the radial sealing and inner ring cover after replacement of the outer ring cover. xx2000002494 6 Check the gasket after removing the outer ring cover. Replace if damaged. xx2000002495 Refitting the tilt unit Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection type Foundry Plus (option 3352-10) Check the M2 variseal sealings on both sides. Replace if damaged. M2 variseal sealing: 3HAC044641008 Note The sealing lip is facing outside of the robot. xx2000002522 Continues on next page Product manual - IRB 1300 449 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued 3 Action Note Refit the tilt unit. Screw: M4x12 12.9 Lafre 2C2B/FC6.9 (12 pcs) Tightening torque: 4.5 Nm xx2000001741 Refitting the tubular support Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) 1 Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063. 2 Apply flange sealing Loctite 574 on the mounting surfaces of the CP/CS connector and wipe clean if there is any overflowing Loctite 574. 3 Refit the tubular support. xx2000002523 Screw: M6x20 12.9 Gleitmo 603+Geomet 500 (6 pcs) Tightening torque: 14 Nm xx2000001740 Refitting the axis-4 gearbox Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 450 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued 2 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the o-rings. Replace if damaged. O-ring on circular spline side, axis 4: 3HAC061327-021 O-ring on flexible spline side, axis 4: 3HAC061327-017 xx2000002525 3 Refit the axis-4 gearbox. xx2000001737 4 Make sure that the screws on the gearbox are properly fitted into the notches on the tubular. xx2000001720 xx2000001738 Continues on next page Product manual - IRB 1300 451 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued 5 Action Note Secure with screws. Screw: M3x35 12.9 Lafre 2C2B/FC6.9 (12 pcs) Tightening torque: 1.9 Nm xx2000001736 Refitting the axis-4 mechanical stop flange Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the axis-4 mechanical stop flange to the gearbox. xx2000001735 3 Make sure that : • the block on the mechanical stop flange is towards the upper side (process hub side). • the notches on the tubular and the mechanical stop flange are aligned. xx2000001678 xx2000001718 Continues on next page 452 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Check the radial sealing on the housing (IP67, Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the housing. Replace if damaged, as described below. xx2000002483 3 Fit the lug plate of the axis-4 sealing assembly tool into the housing with three M4x10 screws. Note Lug plate of the axis-4 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). Pay attention to the location of the lugs. xx2000002484 xx2000002485 4 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. Continues on next page Product manual - IRB 1300 453 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 5 Note Fit the new sealing into the housing. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002486 xx2000002537 6 Fit the circular plate of the axis-4 sealing assembly Circular plate of the axis-4 sealing tool against the sealing and fix with three M6x85 assembly tool, included in Special screws. toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002487 xx2000002488 7 Screw the screws, little by little and evenly, to press the sealing into place. 8 Remove the assembly tool. 9 Check that the sealing is undamaged and properly fitted. Continues on next page 454 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Refitting the axis-4 mechanical stop slider Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Place the axis-4 mechanical stop slider in the housing. xx2000001732 Refitting the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option O-ring on tubular: 3HAC061327018 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Valid for IRB 1300-11/0.9 and IRB 1300-10/1.15 Check the O-ring. Replace if damaged. xx2000002519 3 Refit the tubular to the housing. xx2000001734 Continues on next page Product manual - IRB 1300 455 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued 4 Action Note Refit the screws. Screw: M4x12 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (14 pcs) Tightening torque: 3.3 Nm xx2000001729 Refitting the axis-4 motor Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 3 Install the timing belt to the gearbox pulley and verify that the belt runs correctly in the grooves of the pulley. xx2000001670 4 Orient the motor correctly and fit it into the hous- Motor orientation: orient the motor ing. according to the figure below, in regard to the encircled motor connector. Note Make sure the motor flange does not press on the timing belt. xx2000001607 Continues on next page 456 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 5 Note Refit the motor and verify that the timing belt runs correctly in the groove of the motor pulley. xx2000001680 6 Refit the screws and washers. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (3 pcs) Note Do not tighten the screws yet. xx2000001605 Adjusting the axis-4 timing belt tension Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Remove the screw below the housing. xx2000001609 3 Fit the tension adjustment tool for axis-4 timing belt to the screw hole. Tension adjustment tool for axis-4 timing belt. Included in special toolkit 3HAC076396-001. xx2000001610 Continues on next page Product manual - IRB 1300 457 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Use a handheld dynamometer hooking to the tool. xx2000001611 5 Pull the dynamometer to make the tension falling Used belt: 16.7-19.1 N in the allowed force range. New belt:23.9-26.2 N Note Pay attention to the force application direction. xx2000001612 6 Secure the motor with the screws. Tightening torque: 3.3 Nm±3% xx2000001604 Continues on next page 458 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued 7 Action Note Remove the tool and refit the plug screw. For robots with protection type Clean Room (option 3351-4) Refit the plug screw with the rubber washer. Tightening torque: 3 Nm For robots NOT with protection type Clean Room Plug screw: 3HAC078352-001 xx2000001609 For robots with protection type Clean Room (option 3351-4) Plug screw, Clean Room: 3HAC078351-001 Rubber sealing washer: 3HAC075325-001 xx2000002496 Securing the cable package in the lower arm Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 459 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued 2 Action Note Check the axis-3 cable protector. Replace if damaged. Grease: 3HAC029132-001 Plastic cable protector, axis 3: 3HAC064693-001 Note If replaced, apply grease to the axis-3 cable protector before refitting. xx2000001568 Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 2.6 Nm xx2000001552 3 Route the cable package through the lower arm support and up into the housing. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Routing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Slip the axis-4 cable protector over the cable package. Plastic cable protector, axis 4: 3HAC064694-001: xx2000001570 Continues on next page 460 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note Insert the cable package through the hollow tube of the axis-4 gearbox, into the extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4) and into the tubular. Make sure that: • the air hoses are facing the axis-3 gearbox side in the hollow tube of axis-4 gearbox. CAUTION xx2000001571 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Securing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the axis-4 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001546 Reconnecting the axis-4 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001545 Continues on next page Product manual - IRB 1300 461 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note Reconnect the connectors. • FB4 • MP4 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001544 4 Route and secure the cabling with a cable strap. Note The motor cablings have another strap fixed. Pay attention to the location where the new strap to be fixed, see the figure as a guidance. CAUTION xx2000001543 Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the connector plate. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001542 Routing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 462 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 2 Note Refit the second semicircular bracket to the tubu- Screw: M4x8 12.9 Lafre lar. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001749 3 Route the cablings. • Leave the CP/CS connectors and motor connectors out from the tubular support, and Ethernet connectors and air hoses out from the process hub. • The air hoses are facing upside in the semicircular bracket. Reconnecting the air hoses and Ethernet cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Reconnect the air hoses. Note See the number markings on the air hoses for help to find the corresponding air hoses. xx2000001539 3 For robots with Ethernet cabling Access the connector from the process hub and reconnect the connector. • J1.C2 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001540 Continues on next page Product manual - IRB 1300 463 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Refitting the axis-6 motor Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 3 Orient the motor correctly and fit it into the tubular. Motor orientation: orient the motor according to the figure below, in regard to the encircled motor conTip nector. Leave the axis-6 motor connectors accessible from the tubular support side. xx2000001603 4 Refit the screws and washers. Screw: M5x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Note Do not tighten the screws yet. xx2000001601 Refitting the axis-6 timing belt Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx2000001600 Continues on next page 464 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action Note 3 Move the motor to achieve proper belt tension. Used belt: 85.7-91.6 Hz New belt: 102-107 Hz 4 Use a sonic tension meter to measure the timing belt tension. If the timing belt tension does not meet the requirement, loosen the motor screws and readjust. 5 Secure the motor with the screws. Tightening torque: 6 Nm xx2000001599 Refitting the axis-5 motor Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 3 Orient the motor correctly and fit it into the tubular. Motor orientation: orient the motor according to the figure below, in regard to the encircled motor connector. xx2000001598 Continues on next page Product manual - IRB 1300 465 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued 4 Action Note Refit the screws and washers. Screw: M5x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Note Do not tighten the screws yet. xx2000001596 Refitting the axis-5 timing belt Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx2000001595 3 Move the motor to achieve proper belt tension. 4 Use a sonic tension meter to measure the timing belt tension. If the timing belt tension does not meet the requirement, loosen the motor screws and readjust. 5 Secure the motor with the screws. Used belt: 59.3-63.4 Hz New belt: 70.8-74.3 Hz Tightening torque: 6 Nm xx2000001594 Continues on next page 466 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Reconnecting the CP/CS cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the connectors to the connector plate. xx2000001537 3 For robots with CP/CS cabling Reconnect the connectors. • J1.C1 • J1.C3 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001536 Reconnecting the axis-5 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001535 Continues on next page Product manual - IRB 1300 467 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note Reconnect the connectors. • FB5 • MP5 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001534 Reconnecting the axis-6 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001533 3 Reconnect the connectors. • FB6 • MP6 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001532 Refitting the process hub Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 468 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 2 Note Check the air hoses. Replace the cable package if damaged. See Replacing the cable package on page 148. xx2000001539 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for process hub: 3HAC070887-001 xx2000002512 4 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolts. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002513 5 Refit the process hub. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001538 Continues on next page Product manual - IRB 1300 469 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Securing the cable package in the tubular Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the first semicircular bracket to fix the cable Screw: M4x12 12.9 Lafre package. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001748 3 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each plate) Tightening torque: 1.3 Nm xx2000001531 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001530 Refitting the covers Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 470 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 2 Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gaskets. • Gasket for tubular covers (A) • Gasket for housing cover (B) • Gasket for lower arm support cover (C) Replace if damaged. xx2000002503 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the covers. • Tubular covers (A) • Housing cover (B) • Lower arm support cover (C) Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001733 Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. 3 DANGER Make sure all safety requirements are met when performing the first test run. Continues on next page Product manual - IRB 1300 471 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Refitting the tubular and tilt unit (IRB 1300-7/1.4 and IRB 1300-12/1.4) Use these procedures to refit the tubular and tilt unit for IRB 1300-7/1.4 and IRB 1300-12/1.4. Checking the sealing set on the tilt unit (Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the sealing set on the tilt unit. The sealing set includes an inner ring cover (A), a radial sealing (B), an outer ring cover (C) and a gasket (D). Replace the damaged part as described below: • If the inner ring cover is damaged, proceed to 3. • If the radial sealing is damaged, proceed to 4. • If the outer ring cover is damaged, proceed to 5. • If the gasket is damaged, proceed to 6. 3 xx2000002489 Remove the old inner ring cover and fit the new one with two M3x8 countersunk screws. xx2000002490 Continues on next page 472 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 4 Note Remove the old radial sealing and fit the new one as described below. The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002491 xx2000002537 1. Apply a little grease to the sealing lip when re- Grease: 3HAC029132-001 placing the radial sealing and wipe clean after the replacement. 2. Fit the small cap of the axis-6 sealing assembly Small cap of the axis-6 sealing assembly tool, included in Special tool against inner ring cover and fix with two toolkit for IP67/Clean M6x16 screws. Room/Foundry Plus robots (3HAC078203-001). xx2000002492 3. Fit the big cap of the axis-6 sealing assembly Big cap of the axis-6 sealing astool against the sealing and fix with two M6x25 sembly tool, included in Special toolkit for IP67/Clean screws. Room/Foundry Plus robots (3HAC078203-001). xx2000002493 4. Screw the screws, little by little and evenly, to press the sealing into place. Continues on next page Product manual - IRB 1300 473 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action Note 5. Remove the assembly tool. 6. Check that the sealing is undamaged and properly fitted. 5 Remove the inner ring cover and radial sealing first, then, remove the outer ring cover and fit the new one. Remember to refit the radial sealing and inner ring cover after replacement of the outer ring cover. xx2000002494 6 Check the gasket after removing the outer ring cover. Replace if damaged. xx2000002495 Refitting the tilt unit Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection type Foundry Plus (option 3352-10) Check the M2 variseal sealings on both sides. Replace if damaged. M2 variseal sealing: 3HAC044641008 Note The sealing lip is facing outside of the robot. xx2000002522 Continues on next page 474 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued 3 Action Note Refit the tilt unit. Screw: M4x12 12.9 Lafre 2C2B/FC6.9 (12 pcs) Tightening torque: 4.5 Nm xx2000001741 Refitting the tubular support Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) 1 Remove residual locking liquid and other pollutants with cleaning agent Loctite 7063. 2 Apply flange sealing Loctite 574 on the mounting surfaces of the CP/CS connector and wipe clean if there is any overflowing Loctite 574. 3 Refit the tubular support. xx2000002523 Screw: M6x20 12.9 Gleitmo 603+Geomet 500 (6 pcs) Tightening torque: 14 Nm xx2000001740 Refitting the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 475 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued 2 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the O-ring. Replace if damaged. O-ring on tubular: 3HAC061327018 xx2000002519 3 Refit the tubular and tilt unit to the extender unit. Screw: M4x25 12.9 Lafre 2C2B/FC6.9 (12 pcs) Tightening torque: 3.8 Nm xx2000001739 4 Make sure that the notches on the extender unit and tubular are aligned. xx2000001742 Refitting the axis-6 motor Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page 476 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note Orient the motor correctly and fit it into the tubular. Motor orientation: orient the motor according to the figure below, in regard to the encircled motor conTip nector. Leave the axis-6 motor connectors accessible from the tubular support side. xx2000001603 4 Refit the screws and washers. Screw: M5x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Note Do not tighten the screws yet. xx2000001601 Refitting the axis-6 timing belt Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx2000001600 3 Move the motor to achieve proper belt tension. 4 Use a sonic tension meter to measure the timing belt tension. If the timing belt tension does not meet the requirement, loosen the motor screws and readjust. Used belt: 85.7-91.6 Hz New belt: 102-107 Hz Continues on next page Product manual - IRB 1300 477 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued 5 Action Note Secure the motor with the screws. Tightening torque: 6 Nm xx2000001599 Refitting the axis-5 motor Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 3 Orient the motor correctly and fit it into the tubular. Motor orientation: orient the motor according to the figure below, in regard to the encircled motor connector. xx2000001598 4 Refit the screws and washers. Screw: M5x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Note Do not tighten the screws yet. xx2000001596 Continues on next page 478 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Refitting the axis-5 timing belt Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx2000001595 3 Move the motor to achieve proper belt tension. 4 Use a sonic tension meter to measure the timing belt tension. If the timing belt tension does not meet the requirement, loosen the motor screws and readjust. 5 Secure the motor with the screws. Used belt: 59.3-63.4 Hz New belt: 70.8-74.3 Hz Tightening torque: 6 Nm xx2000001594 Routing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 479 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 2 Note Refit the second semicircular bracket to the tubu- Screw: M4x8 12.9 Lafre lar. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001749 3 Route the cablings. • Leave the CP/CS connectors and motor connectors out from the tubular support, and Ethernet connectors and air hoses out from the process hub. • The air hoses are facing upside in the semicircular bracket. Reconnecting the air hoses and Ethernet cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Reconnect the air hoses. Note See the number markings on the air hoses for help to find the corresponding air hoses. xx2000001539 3 For robots with Ethernet cabling Access the connector from the process hub and reconnect the connector. • J1.C2 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001540 Continues on next page 480 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Reconnecting the CP/CS cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the connectors to the connector plate. xx2000001537 3 For robots with CP/CS cabling Reconnect the connectors. • J1.C1 • J1.C3 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001536 Reconnecting the axis-5 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001535 Continues on next page Product manual - IRB 1300 481 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 3 Note Reconnect the connectors. • FB5 • MP5 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001534 Reconnecting the axis-6 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001533 3 Reconnect the connectors. • FB6 • MP6 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001532 Refitting the process hub Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 482 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 2 Note Check the air hoses. Replace the cable package if damaged. See Replacing the cable package on page 148. xx2000001539 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for process hub: 3HAC070887-001 xx2000002512 4 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolts. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002513 5 Refit the process hub. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001538 Continues on next page Product manual - IRB 1300 483 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Securing the cable package in the tubular Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the first semicircular bracket to fix the cable Screw: M4x12 12.9 Lafre package. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001748 3 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each plate) Tightening torque: 1.3 Nm xx2000001531 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001530 Refitting the tubular covers Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 484 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.3 Replacing the tubular and tilt unit Continued Action 2 Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gaskets. Replace if damaged. xx2000002507 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the tubular covers. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001593 Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. 3 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1300 485 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.4 Replacing the axis-3 mechanical stops 5.5.4 Replacing the axis-3 mechanical stops Location of the mechanical stops The mechanical stops are located as shown in the figure. IRB 1300-11/0.9, IRB 1300-7/1.4 and IRB 1300-12/1.4 IRB 1300-10/1.15 xx2000000408 xx2000000471 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Mechanical stop, block A 3HAC065651-001 Replace if damaged. Mechanical stop, block B 3HAC065671-001 Used for axis 3 of IRB 130010/1.15. Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Consumable Article number Note Locking liquid 3HAB7116-1 Loctite 243 Required tools and equipment Required consumables Continues on next page 486 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.4 Replacing the axis-3 mechanical stops Continued Replacing the axis-3 mechanical stops Action 1 Note Jog the robot to a position where the mechanical stops are most easily accessed. 2 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 3 Remove the mechanical stops. For IRB 1300-11/0.9, IRB 13007/1.4 and IRB 1300-12/1.4 xx2000000507 For IRB 1300-10/1.15 xx2000000508 4 Discard the old stops and refit with new ones. 5 Apply a little Loctite 243 to the screws. For IRB 1300-11/0.9, IRB 13007/1.4 and IRB 1300-12/1.4 Mechanical stop, block A: 3HAC065651-001 (2 pcs) For IRB 1300-10/1.15 Mechanical stop, block A: 3HAC065651-001 (1 pcs) Mechanical stop, block B: 3HAC065671-001 (1 pcs) Note If there is locking liquid residues on the screw, please clean it before refitting. Remove residual locking liquid after refitting. Continues on next page Product manual - IRB 1300 487 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.4 Replacing the axis-3 mechanical stops Continued 6 Action Note Secure the mechanical stops. Screw: M4x16 stainless steel (1 pcs per stop) Tightening torque: 1 Nm 488 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.5 Replacing the axis-4 mechanical stops 5.5.5 Replacing the axis-4 mechanical stops Location of the mechanical stops The mechanical stops are located as shown in the figure. xx2000000409 A Mechanical stop, axis 4, flange B Mechanical stop, axis 4, slider Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Mechanical stop, axis 4, flange 3HAC065805-001 Replace if damaged. Mechanical stop, axis 4, slider 3HAC065804-001 Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Continues on next page Product manual - IRB 1300 489 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.5.5 Replacing the axis-4 mechanical stops Continued Equipment Article number Note Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply Used to release the motor brakes. - Tension adjustment tool for axis-4 timing belt Included in special toolkit 3HAC076396-001. Dynamometer - Used for measuring the timing belt tension. Special toolkit for IP67/Clean Room/Foundry Plus robots 3HAC078203-001 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. Replacement of axis-4 mechanical stops The axis-4 mechanical stops, both flange and slider, are accessible after removing the housing, see Replacing the housing and extender unit on page 359. 490 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor 5.6 Motors 5.6.1 Replacing the axis-1 motor Location of the axis-1 motor The axis-1 motor is located as shown in the figure. xx2000001480 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Motor unit, axis 1 3HAC073039-001 O-ring on motor unit 3HAC061327-037 Main cable harness, S, basic 3HAC073303-001 Note Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page Product manual - IRB 1300 491 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Spare part Article number Note Main cable harness, S (CP/CS and 3HAC073304-001 air hose, without Ethernet) Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, S (CP/CS and 3HAC073305-001 air hose, with Ethernet) Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, M, basic 3HAC073300-001 Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, M (CP/CS and 3HAC073301-001 air hose, without Ethernet) Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, M (CP/CS and 3HAC073302-001 air hose, with Ethernet) Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L, basic 3HAC073297-001 Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L (CP/CS and 3HAC073298-001 air hose, without Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L (CP/CS and 3HAC073299-001 air hose, with Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic 3HAC073306-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page 492 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Spare part Article number Note Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, S, basic, Clean Room 3HAC077833-001 Used with IRB 1300-11/0.9. Used with protection type Clean Room. Main cable harness, S, Clean 3HAC077834-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-11/0.9. Used with protection type Clean Room. Main cable harness, S, Clean Room (CP/CS and air hose, with Ethernet) 3HAC077835-001 Used with IRB 1300-11/0.9. Used with protection type Clean Room. Main cable harness, M, basic, Clean Room 3HAC077830-001 Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, M, Clean 3HAC077831-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, M, Clean Room (CP/CS and air hose, with Ethernet) 3HAC077832-001 Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, L, basic, Clean 3HAC077827-001 Room Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Main cable harness, L, Clean 3HAC077828-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Main cable harness, L, Clean Room (CP/CS and air hose, with Ethernet) 3HAC077829-001 Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Plastic cable protector, axis 2 3HAC067816-001 Plastic cable protector, axis 3 3HAC064693-001 Plastic cable protector, axis 4 3HAC064694-001 Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page Product manual - IRB 1300 493 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Spare part Article number Note Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, short 3HAC073095-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, long 3HAC073096-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing top cover 3HAC073091-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Base cover 3HAC073090-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Base adapter 3HAC073089-001 Used for robots with bottom connector interface. SMB cover 3HAC076475-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Brake release unit 3HAC073296-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Swing cover, short, Clean Room 3HAC077824-001 Used with protection type Clean Room. Swing cover, long, Clean Room 3HAC077825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Swing top cover, Clean Room 3HAC077820-001 Used with protection type Clean Room. Continues on next page 494 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Spare part Article number Note Base cover, Clean Room 3HAC077819-001 Used with protection type Clean Room. SMB cover, Clean Room 3HAC077839-001 Used with protection type Clean Room. Brake release unit, Clean Room 3HAC077826-001 Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for SMB cover 3HAC067820-001 Not used with protection class IP40. Replace if damaged. Gasket for brake release unit 3HAC070274-001 Not used with protection class IP40. Replace if damaged. Gasket for base cover 3HAC067819-001 Not used with protection class IP40. Replace if damaged. Gasket for base adapter 3HAC067818-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Gasket for swing cover, short 3HAC067824-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, long 3HAC067825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Gasket for swing top cover 3HAC067821-001 Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Continues on next page Product manual - IRB 1300 495 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Required tools and equipment Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Oil collecting vessel - The capacity of the vessel must be sufficient to take the complete amount of oil. Connector for quick coupling, with outlet pipe Used for draining and filling oil to axis-1 gearbox. Connector specification: G3/8 Oil dispenser - Includes pump with outlet pipe. Roundsling, 1.7 m - Length: 1.7 m Lifting capacity: >400 kg Overhead crane - Required consumables Consumable Article number Note Cable straps - Grease 3HAC029132-001 FM 222 Lubricating oil 3HAC032140-001 Kyodo Yushi TMO150 Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Continues on next page 496 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Action Note If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Removing the motor Use these procedures to remove the axis-1 motor. Preparations before removing the axis-1 motor Action Note 1 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 497 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Draining oil of axis-1 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. 3 Place the oil collecting vessel underneath the quick coupling. xx2000001514 4 Remove the oil plugs and keep them opened to speed up the drainage. xx2000001513 5 Plug a G3/8 quick coupling connector with pipe to the quick coupling on base. 6 WARNING Used oil is hazardous material and must be disposed of in a safe way. See Decommissioning on page 747 for more information. Continues on next page 498 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Action 7 Note Drain the gearbox oil. Note Draining is time-consuming. Elapsed time varies depending on the temperature of the oil. 8 Remove the quick coupling connector and clean the pipe after the oil is drained. Note There will be some oil left in the gearbox after draining. 9 Refit oil plugs. Tightening torque: 10 Nm Removing the complete cable package Follow the instructions detailed in Removing the cable package on page 155 to remove the complete cable package. Putting the robot on its side Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Run a roundsling around the lower arm. Roundsling, 1.7 m (1 pcs), Lifting capacity: >400 kg xx2000001651 Continues on next page Product manual - IRB 1300 499 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Action Note 4 CAUTION The IRB 1300 robot weighs . IRB 1300-11/0.9: 75 kg IRB 1300-10/1.15: 77 kg IRB 1300-7/1.4: 79 kg IRB 1300-12/1.4: 79 kg All lifting accessories used must be sized accordingly! 5 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. 6 Loosen the robot from the foundation by removing the foundation attachment screws and put the robot on its side. Note Lay the robot down with the lower arm support and swing support towards upside. xx2000001649 Removing the base covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 500 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Action 3 Note Valid for cabling with rear interface Remove the base bottom cover together with the base adapter. xx2000001642 Removing the axis-1 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 WARNING When separating the motor from the gearbox, there may be pressure present in the gearbox, causing lubricant to spray from the opening. Before proceeding, please read the safety information in the section Gearbox lubricants (oil or grease) on page 29. 4 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. 5 Access the screws and washers securing the axis1 motor from the base bottom. xx2000001643 Continues on next page Product manual - IRB 1300 501 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Action 6 Note Remove the screws and washers. xx2000001644 7 Carefully lift out the motor. xx2000001645 Refitting the motor Use these procedures to refit the axis-1 motor. Refitting the axis-1 motor Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 3 Check the O-ring. Replace if damaged. O-ring on motor unit: 3HAC061327037 xx2000001646 Continues on next page 502 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Action 4 Note Apply lubricating oil to the motor that has contact- Kyodo Yushi TMO150: ing area with the gearbox. 3HAC032140-001 xx2000001700 5 Orient the motor correctly and fit it into the swing. Motor orientation: orient the motor Make sure the motor is properly fit to gearbox. according to the figure below, in regard to the encircled motor connector. xx2000001647 6 Refit the screws and washers. Screw: M6x20 12.9 Gleitmo 603+Geomet 500 (4 pcs) Tightening torque: 10 Nm xx2000001644 Refitting the base covers Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 503 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued 2 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Valid for cabling with rear interface Check the gasket. Replace if damaged. Gasket for base adapter: 3HAC067818-001 xx2000002510 3 Valid for cabling with rear interface Screw: M4x10 12.9 Lafre Refit the base bottom cover together with the base 2C2B/FC6.9 (8 pcs) adapter. Tightening torque: 2.6 Nm xx2000001642 Securing the robot to the foundation Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Run a roundsling around the lower arm. Roundsling, 1.7 m, Lifting capacity: >400 kg xx2000001649 Continues on next page 504 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Action Note 3 CAUTION The IRB 1300 robot weighs . IRB 1300-11/0.9: 75 kg IRB 1300-10/1.15: 77 kg IRB 1300-7/1.4: 79 kg IRB 1300-12/1.4: 79 kg All lifting accessories used must be sized accordingly! 4 Raise the robot to standing and secure to the foundation with the attachment screws and washers. Attachment screws: M16x50, quality: 8.8. Washers: 17 x 30 x 3, steel hardness class 200HV. Tightening Torque: 150 Nm±10 Nm. Refitting the complete cable package Follow the instructions detailed in Refitting the cable package on page 171 to refit the complete cable package. Refilling oil to axis-1 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. 3 Open the oil plugs, one for filling and the other for venting. xx2000001513 Continues on next page Product manual - IRB 1300 505 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.1 Replacing the axis-1 motor Continued Action Note 4 WARNING Overfilling of gearbox lubricant can lead to internal over-pressure inside the gearbox which in turn may: • damage seals and gaskets • completely press out seals and gaskets • prevent the robot from moving freely. 5 Refill the gearbox with oil. Note Type of oil and total amount is detailed in Technical reference manual - Lubrication in gearboxes. The amount of oil to be filled depends on the amount previously being drained. 6 Refit the oil plugs. Tightening torque: 10 Nm Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. 3 DANGER Make sure all safety requirements are met when performing the first test run. 506 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor 5.6.2 Replacing the axis-2 motor Location of the axis-2 motor The axis-2 motor is located as shown in the figure. xx2000001481 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Motor unit, axis 2 3HAC073078-001 Used for IRB 1300-11/0.9, IRB 1300-10/1.15 and IRB 1300-7/1.4. Motor unit, axis 2 (IRB 1300-12/1.4) 3HAC082078-001 Used for IRB 1300-12/1.4. O-ring on motor unit 3HAC061327-037 Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, short 3HAC073095-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page Product manual - IRB 1300 507 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Spare part Article number Note Swing cover, long 3HAC073096-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, short, Clean Room 3HAC077824-001 Used with protection type Clean Room. Swing cover, long, Clean Room 3HAC077825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Gasket for swing cover, short 3HAC067824-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, long 3HAC067825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Roundsling, 1.7 m - Length: 1.7 m Lifting capacity: >400 kg Overhead crane - Required consumables Consumable Article number Cable straps - Note Continues on next page 508 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Consumable Article number Note Grease 3HAC029132-001 FM 222 Lubricating oil 3HAC032140-001 Kyodo Yushi TMO150 Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Removing the motor Use these procedures to remove the axis-2 motor. Preparations before removing the axis-2 motor Action 1 Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1300 509 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Action 2 Note Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Putting the robot on its side CAUTION If the axis-2 motor is removed with the robot standing on floor, oil will leak from the axis-2 gearbox. Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 510 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued 3 Action Note Run a roundsling around the lower arm. Roundsling, 1.7 m (1 pcs), Lifting capacity: >400 kg xx2000001650 4 CAUTION The IRB 1300 robot weighs . IRB 1300-11/0.9: 75 kg IRB 1300-10/1.15: 77 kg IRB 1300-7/1.4: 79 kg IRB 1300-12/1.4: 79 kg All lifting accessories used must be sized accordingly! 5 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. 6 Loosen the robot from the foundation by removing the foundation attachment screws and put the robot on its side. Note Lay the robot down with the lower arm support and swing support towards upside. xx2000001648 Removing the covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 511 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the covers. • lower arm support cover • swing support cover xx2000001622 Loosening the cable package Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the cable bracket in the lower arm. xx2000001553 Continues on next page 512 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Action 4 Note Remove the cable bracket in the swing. xx2000001623 Disconnecting the axis-2 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate, as shown in following step. xx2000001548 4 Cut the cable strap. xx2000001640 Continues on next page Product manual - IRB 1300 513 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Action 5 Note Disconnect the connectors. • FB2 • MP2 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001639 6 Snap loose and remove the male head of the connectors from the connector plate. xx2000001641 Removing the axis-2 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 WARNING When separating the motor from the gearbox, there may be pressure present in the gearbox, causing lubricant to spray from the opening. Before proceeding, please read the safety information in the section Gearbox lubricants (oil or grease) on page 29. Continues on next page 514 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Action 4 Note CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. 5 Cut the cable strap. xx2000001624 6 Remove the cable bracket. xx2000001625 7 Wrap the connectors with the masking tape and pull the motor cablings carefully down to the swing from the lower arm. 8 Access the screws and washers securing the axis2 motor from the swing support. xx2000001627 9 Remove the screws and washers. xx2000001626 Continues on next page Product manual - IRB 1300 515 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Action 10 Note Carefully lift out the motor. xx2000001628 Refitting the motor Use these procedures to refit the axis-2 motor. Refitting the axis-2 motor Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 CAUTION Do not mix the axis-2 motor used for IRB 13007/1.4 and IRB 1300-12/1.4. Always carefully check the part number attached to the motor and the robot type, and refit with the right one. 3 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 4 Check the O-ring. Replace if damaged. Axis-2 motor for IRB 1300-7/1.4: 3HAC073078-001 Axis-2 motor for IRB 1300-12/1.4: 3HAC082078-001 O-ring on motor unit: 3HAC061327037 xx2000001629 Continues on next page 516 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Action 5 Note Apply lubricating oil to the motor that has contact- Kyodo Yushi TMO150: ing area with the gearbox. 3HAC032140-001 xx2000001701 6 Orient the motor correctly and fit it into the swing. Motor orientation: orient the motor Make sure the motor is properly fit to gearbox. according to the figure below, in regard to the encircled motor connector. xx2000001630 7 Refit the screws and washers. Screw: M6x20 12.9 Gleitmo 603+Geomet 500 (4 pcs) Tightening torque: 10 Nm xx2000001626 Securing the motor cabling Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 517 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued 2 Action Note Refit the cable bracket. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001625 3 Secure the FB2 cabling to the bracket with cable strap. xx2000001624 4 Wrap the connectors and route the cablings up into the lower arm. Reconnecting the axis-2 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001641 3 Route and secure the cabling with a cable strap. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001640 Continues on next page 518 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Action 4 Note Reconnect the connectors. • FB2 • MP2 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001639 5 Refit the connector plate to the lower arm. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001548 Securing the cable package Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the cable bracket in the swing. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001623 Continues on next page Product manual - IRB 1300 519 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued 3 Action Note Refit the cable bracket in the lower arm. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001553 Refitting the covers Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gaskets. Replace if damaged. xx2000002504 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the covers. • lower arm support cover • swing support cover Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001622 Continues on next page 520 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Securing the robot to the foundation Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Run a roundsling around the lower arm. Roundsling, 1.7 m, Lifting capacity: >400 kg xx2000001648 3 CAUTION The IRB 1300 robot weighs . IRB 1300-11/0.9: 75 kg IRB 1300-10/1.15: 77 kg IRB 1300-7/1.4: 79 kg IRB 1300-12/1.4: 79 kg All lifting accessories used must be sized accordingly! 4 Raise the robot to standing and secure to the foundation with the attachment screws and washers. Attachment screws: M16x50, quality: 8.8. Washers: 17 x 30 x 3, steel hardness class 200HV. Tightening Torque: 150 Nm±10 Nm. Action Note Concluding procedure 1 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. Continues on next page Product manual - IRB 1300 521 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.2 Replacing the axis-2 motor Continued Action Note 3 DANGER Make sure all safety requirements are met when performing the first test run. 522 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.3 Replacing the axis-3 motor 5.6.3 Replacing the axis-3 motor Location of the axis-3 motor The axis-3 motor is located as shown in the figure. xx2000001482 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Motor unit, axis 3 3HAC073086-001 Used for IRB 1300-11/0.9, IRB 1300-10/1.15 and IRB 1300-7/1.4. Motor unit, axis 3 (IRB 1300-12/1.4) 3HAC082079-001 Used for IRB 1300-12/1.4. Resolver cover on motor (IRB 1300-12/1.4) 3HAC060261-001 Used for IRB 1300-12/1.4. Timing belt, axis 3 3HAC067040-001 Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Continues on next page Product manual - IRB 1300 523 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.3 Replacing the axis-3 motor Continued Spare part Article number Note Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Sonic tension meter - Used for measuring the timing belt tension. Consumable Article number Note Cable straps - Grease 3HAC029132-001 Required consumables FM 222 Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page 524 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.3 Replacing the axis-3 motor Continued Removing the motor Use these procedures to remove the axis-3 motor. Preparations before removing the axis-3 motor Action Note 1 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Removing the lower arm covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 525 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.3 Replacing the axis-3 motor Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the lower arm covers. xx2000001613 Disconnecting the axis-3 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate, as shown in following step. xx2000001548 Continues on next page 526 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.3 Replacing the axis-3 motor Continued Action 4 Note Cut the cable strap. xx2000001620 5 Disconnect the connectors. • FB3 • MP3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001619 6 Snap loose and remove the male head of the connectors from the connector plate. xx2000001621 Removing the axis-3 timing belt Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 527 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.3 Replacing the axis-3 motor Continued Action 3 Note CAUTION Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. 4 CAUTION The upper arms, which includes housing, extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4), tubular and tilt unit weighs 17 kg. All lifting accessories used must be sized accordingly! 5 Fit a roundsling to the upper arm to support the weight (no force). 6 Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001614 7 Remove the timing belt from its groove on the motor. xx2000001615 Removing the axis-3 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 528 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.3 Replacing the axis-3 motor Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. 4 Remove the screws and washers. xx2000001616 5 Carefully lift out the motor. xx2000001617 Refitting the motor Use these procedures to refit the axis-3 motor. Refitting the axis-3 motor Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 529 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.3 Replacing the axis-3 motor Continued Action Note 2 CAUTION Do not mix the axis-3 motor used for IRB 13007/1.4 and IRB 1300-12/1.4. Always carefully check the part number attached to the motor and the robot type, and refit with the right one. 3 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 4 Valid for IRB 1300-12/1.4 Check the resolver cover. Replace if damaged. Axis-3 motor for IRB 1300-7/1.4: 3HAC073086-001 Axis-3 motor for IRB 1300-12/1.4: 3HAC082079-001 Resolver cover on motor (IRB 1300-12/1.4): 3HAC060261-001 xx2100002770 5 Orient the motor correctly and fit it into the lower Motor orientation: orient the motor arm. according to the figure below, in regard to the encircled motor connector. xx2000001618 6 Refit the screws and washers. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Note Do not tighten the screws yet. xx2000001616 Continues on next page 530 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.3 Replacing the axis-3 motor Continued Refitting the axis-3 timing belt Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx2000001615 3 Move the motor to achieve proper belt tension. 4 Use a sonic tension meter to measure the timing belt tension. If the timing belt tension does not meet the requirement, loosen the motor screws and readjust. 5 Secure the motor with the screws. Used belt: 73.4-78.5 Hz New belt: 87.8-92.1 Hz Tightening torque: 3.3 Nm xx2000001614 6 Release the support to the upper arm. Reconnecting the axis-3 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001621 Continues on next page Product manual - IRB 1300 531 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.3 Replacing the axis-3 motor Continued Action 3 Note Route and secure the cabling with a cable strap. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001620 4 Reconnect the connectors. • FB3 • MP3 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001619 5 Refit the connector plate to the lower arm. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001548 Refitting the lower arm covers Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 532 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.3 Replacing the axis-3 motor Continued Action 2 Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gaskets. Replace if damaged. xx2000002505 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the lower arm covers. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001613 Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. 3 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1300 533 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.4 Replacing the axis-4 motor 5.6.4 Replacing the axis-4 motor Location of the axis-4 motor The axis-4 motor is located as shown in the figure. xx2000001483 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Motor unit, axis 4 3HAC073087-001 Timing belt, axis 4 3HAC065806-001 Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Continues on next page 534 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.4 Replacing the axis-4 motor Continued Required tools and equipment Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply Used to release the motor brakes. - Tension adjustment tool for axis-4 timing belt Included in special toolkit 3HAC076396-001. Dynamometer - Used for measuring the timing belt tension. Consumable Article number Note Cable straps - Grease 3HAC029132-001 Required consumables FM 222 Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 1300 535 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.4 Replacing the axis-4 motor Continued Removing the motor Use these procedures to remove the axis-4 motor. Preparations before removing the axis-4 motor Action Note 1 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Removing the housing cover Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 536 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.4 Replacing the axis-4 motor Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the housing cover. xx2000001541 Disconnecting the axis-4 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001542 Continues on next page Product manual - IRB 1300 537 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.4 Replacing the axis-4 motor Continued Action 4 Note Cut the cable strap. Note The motor cablings have another strap fixed. Always cut the strap that fixes the cable package to the plate. xx2000001543 5 Disconnect the connectors. • MP4 • FB4 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001544 6 Snap loose and remove the male head of the connectors from the connector plate. xx2000001545 Removing the axis-4 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 538 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.4 Replacing the axis-4 motor Continued Action 3 Note CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. 4 Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001604 5 Remove the timing belt from its groove on the motor. 6 Remove the screws and washers. xx2000001605 7 Carefully lift out the motor. xx2000001606 Refitting the motor Use these procedures to refit the axis-4 motor. Refitting the axis-4 motor Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 539 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.4 Replacing the axis-4 motor Continued Action Note 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 3 Orient the motor correctly and fit it into the hous- Motor orientation: orient the motor ing. according to the figure below, in regard to the encircled motor connector. Note Make sure the motor flange does not press on the timing belt. xx2000001607 4 Install the timing belt to the motor pulley and verify that the belt runs correctly in the grooves of the pulley. xx2000001608 5 Refit the screws and washers. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (3 pcs) Note Do not tighten the screws yet. xx2000001605 Adjusting the axis-4 timing belt tension Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 540 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.4 Replacing the axis-4 motor Continued Action 2 Note Remove the screw below the housing. xx2000001609 3 Fit the tension adjustment tool for axis-4 timing belt to the screw hole. Tension adjustment tool for axis-4 timing belt. Included in special toolkit 3HAC076396-001. xx2000001610 4 Use a handheld dynamometer hooking to the tool. xx2000001611 5 Pull the dynamometer to make the tension falling Used belt: 16.7-19.1 N in the allowed force range. New belt:23.9-26.2 N Note Pay attention to the force application direction. xx2000001612 Continues on next page Product manual - IRB 1300 541 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.4 Replacing the axis-4 motor Continued 6 Action Note Secure the motor with the screws. Tightening torque: 3.3 Nm±3% xx2000001604 7 Remove the tool and refit the plug screw. For robots with protection type Clean Room (option 3351-4) Refit the plug screw with the rubber washer. Tightening torque: 3 Nm For robots NOT with protection type Clean Room Plug screw: 3HAC078352-001 xx2000001609 For robots with protection type Clean Room (option 3351-4) Plug screw, Clean Room: 3HAC078351-001 Rubber sealing washer: 3HAC075325-001 xx2000002496 Reconnecting the axis-4 motor connectors Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 542 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.4 Replacing the axis-4 motor Continued Action 2 Note Insert the male header of the motor connectors to the connector plate. xx2000001545 3 Reconnect the connectors. • FB4 • MP4 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001544 4 Route and secure the cabling with a cable strap. Note The motor cablings have another strap fixed. Pay attention to the location where the new strap to be fixed, see the figure as a guidance. CAUTION xx2000001543 Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the connector plate. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001542 Continues on next page Product manual - IRB 1300 543 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.4 Replacing the axis-4 motor Continued Refitting the housing cover Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. xx2000002511 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the housing cover. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001541 Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. 3 DANGER Make sure all safety requirements are met when performing the first test run. 544 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor 5.6.5 Replacing the axis-5 motor Location of the axis-5 motor The axis-5 motor is located as shown in the figure. xx2000001485 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Motor unit, axis 5 and axis 6 3HAC073088-001 Timing belt, axis 5 3HAC065794-001 Process hub, basic 3HAC073306-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic, Clean Room Used with protection type Clean Room. 3HAC077836-001 Note Continues on next page Product manual - IRB 1300 545 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Spare part Article number Note Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Sonic tension meter - Used for measuring the timing belt tension. Consumable Article number Note Cable straps - Grease 3HAC029132-001 Required consumables FM 222 Continues on next page 546 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Removing the motor Use these procedures to remove the axis-5 motor. Preparations before removing the axis-5 motor Action 1 Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1300 547 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Action 2 Note Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Removing the tubular covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 548 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Action 3 Note Remove the tubular covers. xx2000001593 Loosening the process hub Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws and carefully open the cover. CAUTION There is cabling attached to the cover. The cover cannot be removed completely. xx2000001538 Loosening the cables in the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 549 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Cut the cable straps. xx2000001530 4 Remove the connector plates. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001531 Disconnecting the axis-6 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 550 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Action 3 Note Disconnect the connectors. • MP6 • FB6 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001532 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001533 Disconnecting the axis-5 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 551 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Action 3 Note Disconnect the connectors. • MP5 • FB5 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001534 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001535 Disconnecting CP/CS cabling (if equipped) Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 For robots with CP/CS cabling Disconnect the connectors. • J1.C1 • J1.C3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001536 Continues on next page 552 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Action 4 Note Snap loose and remove the male head of the connectors from the connector plate. xx2000001537 Removing the axis-5 timing belt Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. 4 Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001594 Continues on next page Product manual - IRB 1300 553 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Action 5 Note Remove the timing belt from its groove on the motor. xx2000001595 Removing the axis-5 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. 4 Remove the screws and washers. xx2000001596 Continues on next page 554 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Action 5 Note Carefully lift out the motor. xx2000001597 Refitting the motor Use these procedures to refit the axis-5 motor. Refitting the axis-5 motor Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 3 Orient the motor correctly and fit it into the tubular. Motor orientation: orient the motor according to the figure below, in regard to the encircled motor connector. xx2000001598 4 Refit the screws and washers. Screw: M5x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Note Do not tighten the screws yet. xx2000001596 Continues on next page Product manual - IRB 1300 555 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Refitting the axis-5 timing belt Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx2000001595 3 Move the motor to achieve proper belt tension. 4 Use a sonic tension meter to measure the timing belt tension. If the timing belt tension does not meet the requirement, loosen the motor screws and readjust. 5 Secure the motor with the screws. Used belt: 59.3-63.4 Hz New belt: 70.8-74.3 Hz Tightening torque: 6 Nm xx2000001594 Reconnecting the CP/CS cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the connectors to the connector plate. xx2000001537 Continues on next page 556 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Action 3 Note For robots with CP/CS cabling Reconnect the connectors. • J1.C1 • J1.C3 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001536 Reconnecting the axis-5 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001535 3 Reconnect the connectors. • FB5 • MP5 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001534 Reconnecting the axis-6 motor connectors Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 557 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Action 2 Note Insert the male header of the motor connectors to the connector plate. xx2000001533 3 Reconnect the connectors. • FB6 • MP6 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001532 Securing the cable package in the tubular Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each plate) Tightening torque: 1.3 Nm xx2000001531 3 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001530 Continues on next page 558 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Refitting the process hub Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the air hoses. Replace the cable package if damaged. See Replacing the cable package on page 148. xx2000001539 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for process hub: 3HAC070887-001 xx2000002512 4 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolts. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002513 5 Refit the process hub. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001538 Continues on next page Product manual - IRB 1300 559 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Refitting the tubular covers Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gaskets. Replace if damaged. xx2000002507 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the tubular covers. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001593 Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. Continues on next page 560 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.5 Replacing the axis-5 motor Continued Action Note 3 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1300 561 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor 5.6.6 Replacing the axis-6 motor Location of the axis-6 motor The axis-6 motor is located as shown in the figure. xx2000001484 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Motor unit, axis 5 and axis 6 3HAC073088-001 Timing belt, axis 6 3HAC065788-001 Process hub, basic 3HAC073306-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page 562 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Spare part Article number Note Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Sonic tension meter - Used for measuring the timing belt tension. Consumable Article number Note Cable straps - Grease 3HAC029132-001 Required consumables FM 222 Continues on next page Product manual - IRB 1300 563 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Removing the axis-6 motor Use these procedures to remove the axis-6 motor. Preparations before removing the axis-6 motor Action 1 Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page 564 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Action 2 Note Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Removing the tubular covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 565 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Action 3 Note Remove the tubular covers. xx2000001593 Loosening the process hub Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws and carefully open the cover. CAUTION There is cabling attached to the cover. The cover cannot be removed completely. xx2000001538 Loosening the cables in the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 566 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Cut the cable strap. xx2100001483 4 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2100001484 Disconnecting the axis-6 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 567 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Action 3 Note Disconnect the connectors. • MP6 • FB6 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001532 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001533 Removing the axis-5 timing belt Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. Continues on next page 568 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Action 4 Note Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001594 5 Remove the timing belt from its groove on the motor. xx2000001595 Removing the axis-6 timing belt Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. Continues on next page Product manual - IRB 1300 569 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Action 4 Note Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001599 5 Remove the timing belt from its groove on the motor. xx2000001600 Removing the axis-6 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. Continues on next page 570 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Action 4 Note Remove the screws and washers. xx2000001601 5 Carefully lift out the motor. xx2000001602 Refitting the axis-6 motor Use these procedures to refit the axis-6 motor. Refitting the axis-6 motor Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 3 Orient the motor correctly and fit it into the tubular. Motor orientation: orient the motor according to the figure below, in regard to the encircled motor conTip nector. Leave the axis-6 motor connectors accessible from the tubular support side. xx2000001603 Continues on next page Product manual - IRB 1300 571 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued 4 Action Note Refit the screws and washers. Screw: M5x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Note Do not tighten the screws yet. xx2000001601 Refitting the axis-6 timing belt Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx2000001600 3 Move the motor to achieve proper belt tension. 4 Use a sonic tension meter to measure the timing belt tension. If the timing belt tension does not meet the requirement, loosen the motor screws and readjust. 5 Secure the motor with the screws. Used belt: 85.7-91.6 Hz New belt: 102-107 Hz Tightening torque: 6 Nm xx2000001599 Continues on next page 572 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Refitting the axis-5 timing belt Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx2000001595 3 Move the motor to achieve proper belt tension. 4 Use a sonic tension meter to measure the timing belt tension. If the timing belt tension does not meet the requirement, loosen the motor screws and readjust. 5 Secure the motor with the screws. Used belt: 59.3-63.4 Hz New belt: 70.8-74.3 Hz Tightening torque: 6 Nm xx2000001594 Reconnecting the axis-6 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001533 Continues on next page Product manual - IRB 1300 573 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Action 3 Note Reconnect the connectors. • FB6 • MP6 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001532 Securing the cable package in the tubular Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 1.3 Nm xx2100001484 3 Route and secure the cabling with a cable strap. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2100001483 Refitting the process hub Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 574 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Action 2 Note Check the air hoses. Replace the cable package if damaged. See Replacing the cable package on page 148. xx2000001539 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for process hub: 3HAC070887-001 xx2000002512 4 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolts. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002513 5 Refit the process hub. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001538 Continues on next page Product manual - IRB 1300 575 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Refitting the tubular covers Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gaskets. Replace if damaged. xx2000002507 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the tubular covers. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001593 Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. Continues on next page 576 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.6.6 Replacing the axis-6 motor Continued Action Note 3 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1300 577 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.1 Replacing the axis-1 gearbox 5.7 Gearboxes 5.7.1 Replacing the axis-1 gearbox Location of the axis-1 gearbox The axis-1 gearbox is located as shown in the figure. xx2000001486 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Gear unit, axis 1 3HAC063187-001 O-ring on axis-1 gear unit 3HAC063187-007 Motor unit, axis 1 3HAC073039-001 O-ring on motor unit 3HAC061327-037 Radial sealing 3HAC066433-001 Radial sealing 3HAC070148-002 Gasket on swing 3HAC067626-001 Mechanical stop, axis 1, fixed block 3HAC064478-001 Note Replace if damaged. Continues on next page 578 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.1 Replacing the axis-1 gearbox Continued Spare part Article number Note Mechanical stop, axis 1, slider 3HAC065755-001 Replace if damaged. Main cable harness, S, basic 3HAC073303-001 Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, S (CP/CS and 3HAC073304-001 air hose, without Ethernet) Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, S (CP/CS and 3HAC073305-001 air hose, with Ethernet) Used with IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, M, basic 3HAC073300-001 Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, M (CP/CS and 3HAC073301-001 air hose, without Ethernet) Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, M (CP/CS and 3HAC073302-001 air hose, with Ethernet) Used with IRB 1300-10/1.15. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L, basic 3HAC073297-001 Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L (CP/CS and 3HAC073298-001 air hose, without Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, L (CP/CS and 3HAC073299-001 air hose, with Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page Product manual - IRB 1300 579 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.1 Replacing the axis-1 gearbox Continued Spare part Article number Note Process hub, basic 3HAC073306-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Main cable harness, S, basic, Clean Room 3HAC077833-001 Used with IRB 1300-11/0.9. Used with protection type Clean Room. Main cable harness, S, Clean 3HAC077834-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-11/0.9. Used with protection type Clean Room. Main cable harness, S, Clean Room (CP/CS and air hose, with Ethernet) 3HAC077835-001 Used with IRB 1300-11/0.9. Used with protection type Clean Room. Main cable harness, M, basic, Clean Room 3HAC077830-001 Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, M, Clean 3HAC077831-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, M, Clean Room (CP/CS and air hose, with Ethernet) 3HAC077832-001 Used with IRB 1300-10/1.15. Used with protection type Clean Room. Main cable harness, L, basic, Clean 3HAC077827-001 Room Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Main cable harness, L, Clean 3HAC077828-001 Room (CP/CS and air hose, without Ethernet) Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Main cable harness, L, Clean Room (CP/CS and air hose, with Ethernet) 3HAC077829-001 Used with IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Plastic cable protector, axis 2 3HAC067816-001 Continues on next page 580 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.1 Replacing the axis-1 gearbox Continued Spare part Article number Note Plastic cable protector, axis 3 3HAC064693-001 Plastic cable protector, axis 4 3HAC064694-001 Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, short 3HAC073095-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, long 3HAC073096-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing top cover 3HAC073091-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Base cover 3HAC073090-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. SMB cover 3HAC076475-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Brake release unit 3HAC073296-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Swing cover, short, Clean Room 3HAC077824-001 Used with protection type Clean Room. Continues on next page Product manual - IRB 1300 581 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.1 Replacing the axis-1 gearbox Continued Spare part Article number Note Swing cover, long, Clean Room 3HAC077825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Swing top cover, Clean Room 3HAC077820-001 Used with protection type Clean Room. Base cover, Clean Room 3HAC077819-001 Used with protection type Clean Room. SMB cover, Clean Room 3HAC077839-001 Used with protection type Clean Room. Brake release unit, Clean Room 3HAC077826-001 Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for SMB cover 3HAC067820-001 Not used with protection class IP40. Replace if damaged. Gasket for brake release unit 3HAC070274-001 Not used with protection class IP40. Replace if damaged. Gasket for base cover 3HAC067819-001 Not used with protection class IP40. Replace if damaged. Gasket for base adapter 3HAC067818-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Gasket for swing cover, short 3HAC067824-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, long 3HAC067825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Gasket for swing top cover 3HAC067821-001 Not used with protection class IP40. Replace if damaged. Continues on next page 582 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.1 Replacing the axis-1 gearbox Continued Spare part Article number Note Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Radial sealing on swing (to base) 3HAC070148-003 Used with protection types Clean Room and Foundry Plus. Replace if damaged. Required tools and equipment Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Oil collecting vessel - The capacity of the vessel must be sufficient to take the complete amount of oil. Connector for quick coupling, with outlet pipe Used for draining and filling oil to axis-1 gearbox. Connector specification: G3/8 Oil dispenser - Includes pump with outlet pipe. Axis-1 gearbox assembly cap - Included in special toolkit 3HAC076396-001. Roundsling, 1.7 m - Length: 1.7 m Lifting capacity: >400 kg Overhead crane - Special toolkit for IP67/Clean Room/Foundry Plus robots 3HAC078203-001 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. Consumable Article number Note Cable straps - Grease 3HAC029132-001 FM 222 Lubricating oil 3HAC032140-001 Kyodo Yushi TMO150 Required consumables Flange sealant for conical fittings - Loctite 577 Continues on next page Product manual - IRB 1300 583 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.1 Replacing the axis-1 gearbox Continued Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Replacement of the axis-1 gearbox The axis-1 gearbox is accessible after removing the base, see Replacing the base on page 208. 584 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox 5.7.2 Replacing the axis-2 gearbox Location of the axis-2 gearbox The axis-2 gearbox is located as shown in the figure. xx2000001487 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Gear unit, axis 2 3HAC064977-001 O-ring on axis-2 gear unit 3HAC064977-004 Motor unit, axis 2 3HAC073078-001 Motor unit, axis 2 (IRB 1300-12/1.4) 3HAC082078-001 O-ring on motor unit 3HAC061327-037 Process hub, basic 3HAC073306-001 Note Used for IRB 1300-11/0.9, IRB 1300-10/1.15 and IRB 1300-7/1.4. Used for IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page Product manual - IRB 1300 585 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Spare part Article number Note Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Plastic cable protector, axis 2 3HAC067816-001 Plastic cable protector, axis 3 3HAC064693-001 Plastic cable protector, axis 4 3HAC064694-001 Swing support, short 3HAC073041-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing support, short, Clean Room 3HAC077808-001 Used for IRB 1300-11/0.9. Used with protection type Clean Room. Swing support, long 3HAC073052-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing support, long, Clean Room 3HAC077810-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Sealing ring, swing support side 3HAC065676-001 O-ring on swing 3HAC061327-036 Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page 586 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Spare part Article number Note Swing cover, short 3HAC073095-001 Used for IRB 1300-11/0.9. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Swing cover, long 3HAC073096-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Swing cover, short, Clean Room 3HAC077824-001 Used with protection type Clean Room. Swing cover, long, Clean Room 3HAC077825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Gasket for swing support, short 3HAC067822-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Gasket for swing support, long 3HAC067823-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Gasket for swing cover, short 3HAC067824-001 Used for IRB 1300-11/0.9. Not used with protection class IP40. Replace if damaged. Continues on next page Product manual - IRB 1300 587 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Spare part Article number Note Gasket for swing cover, long 3HAC067825-001 Used for IRB 1300-10/1.15, IRB 1300-7/1.4 and IRB 1300-12/1.4. Not used with protection class IP40. Replace if damaged. Gasket for swing top cover 3HAC067821-001 Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Radial sealing on swing (to lower 3HAC070148-004 arm) Not used with protection class IP40. Replace if damaged. Sealing ring, swing side 3HAC065675-001 Used with protection class IP67 and protection type Foundry Plus. O-ring on lower arm 3HAC061327-015 Not used with protection class IP40. Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Oil collecting vessel - The capacity of the vessel must be sufficient to take the complete amount of oil. Oil dispenser - Includes pump with outlet pipe. Guide pin for axis-2 gearbox - Included in special toolkit 3HAC076396-001. Roundsling, 1.7 m - Length: 1.7 m Lifting capacity: >400 kg Overhead crane - Special toolkit for IP67/Clean Room/Foundry Plus robots 3HAC078203-001 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. Continues on next page 588 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Required consumables Consumable Article number Note Cable straps - Grease 3HAC029132-001 FM 222 Lubricating oil 3HAC032140-001 Kyodo Yushi TMO150 Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Removing the gearbox Use these procedures to remove the axis-2 gearbox. Preparations before removing the axis-2 gearbox Action 1 Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 589 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Jogging the robot to oil draining position Action 1 Note Jog the robot to the specified position: • Axis 1: 0° • Axis 2: -67.5 • Axis 3: 0° • Axis 4: 0° • Axis 5: 0° • Axis 6: No significance. xx2000001519 2 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Draining oil of axis-2 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. Continues on next page 590 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 3 Note Place the oil collecting vessel underneath the oil plug, draining. xx2000001515 4 Remove the oil plug, draining. xx2000001516 5 Plug a clean pipe to the oil plug, draining, with the other end to the oil collecting vessel. 6 Remove the oil plug, venting and keep it opened to speed up the drainage. xx2000001517 7 WARNING Used oil is hazardous material and must be disposed of in a safe way. See Decommissioning on page 747 for more information. 8 Drain the gearbox oil. Note Draining is time-consuming. Elapsed time varies depending on the temperature of the oil. Continues on next page Product manual - IRB 1300 591 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 9 Note Remove and clean the pipe after the oil is drained. Note There will be some oil left in the gearbox after draining. 10 Refit oil plugs. Tightening torque: 10 Nm Jogging the robot to zero position Action Note 1 Turn on the electric power to the robot. If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to Supplying power to connector R1.MP on page 66. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Removing the covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 592 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm support cover (C) • Swing covers (D) xx2000001682 Loosening the cables in the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Cut the cable straps. xx2000001530 Continues on next page Product manual - IRB 1300 593 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 4 Note Remove the connector plates. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001531 Disconnecting the axis-6 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP6 • FB6 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001532 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001533 Continues on next page 594 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Disconnecting the axis-5 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP5 • FB5 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001534 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001535 Disconnecting CP/CS cabling (if equipped) Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 595 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 For robots with CP/CS cabling Disconnect the connectors. • J1.C1 • J1.C3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001536 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001537 Separating the cable package from the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 596 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 3 Note Remove the first semicircular bracket that fixes the cable package. xx2000001748 4 Remove the second semicircular bracket from the tubular. xx2000001749 Removing the process hub Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws and carefully open the cover. CAUTION There is cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. xx2000001538 Continues on next page Product manual - IRB 1300 597 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 4 Note Disconnect the air hoses. xx2000001539 5 For robots with Ethernet cabling Access the connector from the process hub and disconnect the connector. • J1.C2 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001540 Tip The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Disconnecting the axis-4 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 598 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001542 4 Cut the cable strap. Note The motor cablings have another strap fixed. Always cut the strap that fixes the cable package to the plate. xx2000001543 5 Disconnect the connectors. • MP4 • FB4 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001544 6 Snap loose and remove the male head of the connectors from the connector plate. xx2000001545 Continues on next page Product manual - IRB 1300 599 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Separating the cable package from the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the axis-4 cable protector. xx2000001546 Disconnecting the axis-2 and -3 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate, as shown in following step. xx2000001548 Continues on next page 600 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 4 Note Cut the cable straps. xx2000001549 5 Disconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. 6 xx2000001550 Snap loose and remove the male head of the connectors from the connector plate. xx2000001551 Separating the cable package from the lower arm Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 601 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 3 Note Remove the cable bracket from the lower arm first and then from the cable package. xx2000001553 xx2100001465 4 Remove the connector plate. xx2000001554 Separating the cable package from the swing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 602 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 3 Note Remove the axis-2 cable protector. xx2000001556 4 Remove the cable brackets from the swing first and then from the cable package. xx2000001557 xx2100001466 Pulling out the cable package Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Wrap the connectors with the masking tape. Continues on next page Product manual - IRB 1300 603 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 4 Note Pull the cable package out to the swing support. xx2000001683 Removing the swing support Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the swing support. Tip If the lower arm support is hard to loosen from the swing, use a plastic hammer to knock on the lower arm support lightly. xx2000001684 Supporting the lower and upper arms with roundslings Note The lower and upper arms include the lower arm, housing, extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4), tubular and tilt unit. Continues on next page 604 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Run two roundslings between the housing and the lower arm. Roundsling, 1.7 m (2 pcs), Lifting capacity: >400 kg xx2000001685 4 CAUTION The lower and upper arms weighs 38 kg. All lifting accessories used must be sized accordingly! 5 WARNING The robot is likely to be mechanically unstable if not secured to the foundation! 6 WARNING Personnel must not, under any circumstances, be present under the suspended load. Continues on next page Product manual - IRB 1300 605 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 7 Note Stretch the roundslings to take the weight of the lower and upper arms. Note Do not stretch the roundslings too much. Removing the axis-2 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 WARNING When separating the motor from the gearbox, there may be pressure present in the gearbox, causing lubricant to spray from the opening. Before proceeding, please read the safety information in the section Gearbox lubricants (oil or grease) on page 29. 4 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. 5 Cut the cable strap. xx2000001624 Continues on next page 606 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 6 Note Remove the cable bracket. xx2000001625 7 Access the screws and washers securing the axis2 motor from the swing support. xx2000001627 8 Remove the screws and washers. xx2000001626 9 Carefully lift out the motor. xx2000001628 Separating the swing from the lower arm Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 607 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws. xx2000001686 4 Separate the swing from the lower arm. Tip If the swing is hard to loosen from the lower arm, use a plastic hammer to knock on the swing lightly. xx2000001687 Removing the axis-2 sealing ring on the swing side Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 608 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 3 Note For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) Remove the sealing ring on the swing side. xx2000002516 Removing the axis-2 gearbox Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing gearboxes will release axes. This means the axes can fall down. Make sure axes are well supported before removing gearboxes. 4 Remove the screws. xx2000001688 Continues on next page Product manual - IRB 1300 609 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 5 Note Pull out the gearbox. xx2000001689 Refitting the gearbox Use these procedures to refit the axis-2 gearbox. Refitting the axis-2 gearbox Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the O-ring. Replace if damaged. O-ring on axis-2 gear unit: 3HAC064977-004 xx2000001690 3 Fit guide pins to the axis-2 gearbox. Note Guide pin for axis-2 gearbox. Included in special toolkit 3HAC076396-001. Always use two guide pins together. xx2000001705 Continues on next page 610 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 4 Note Refit the axis-2 gearbox, with guidance from the guide pins. xx2000001706 5 Secure with screws. Screw: M5x25 12.9 Lafre 2C2B/FC6.9 (16 pcs) Tightening torque: 8.9 Nm±3% xx2000001707 6 Remove the guide pins. xx2000001708 Check the radial sealing on the swing top (Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the swing top. Replace if damaged, as described below. xx2000002460 Continues on next page Product manual - IRB 1300 611 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 3 Note Fit the big circular plate of the axis-2 sealing as- Big circular plate of the axis-2 sembly tool to the swing (opposite side of the ra- sealing assembly tool, included in dial sealing) with three M4x12 screws. Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002461 4 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. 5 Fit the new sealing into the swing. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002462 xx2000002537 Continues on next page 612 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued 6 Action Note For robots with protection type Foundry Plus (option 3352-10) Place the ring of the axis-2 sealing assembly tool against the sealing. Ring of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002463 xx2000002562 7 Fit the small circular plate of the axis-2 sealing assembly tool and fix with three M6x75 screws. Small circular plate of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002464 xx2000002465 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Continues on next page Product manual - IRB 1300 613 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Refitting the swing to the lower arm Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) Check the sealing ring. Replace if damaged. For robots with protection type Foundry Plus (option 3352-10) Check the sealing ring and the O-ring. Replace if damaged. O-ring on lower arm: 3HAC061327015 Sealing ring, swing side: 3HAC065675-001 Screw: M4x12 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 3.8 Nm For robots with protection class IP67 (option 3350-670) xx2000002516 For robots with protection type Foundry Plus (option 3352-10) xx2000002527 3 Check the O-ring. Replace if damaged. O-ring on swing: 3HAC061327-036 xx2000001750 Continues on next page 614 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued 4 Action Note Refit the swing to the lower arm. M10 screws Screw: M10x25 12.9 Gleitmo 603+Geomet 500 (6 pcs) Tightening torque: 72 Nm M6 screws Screw: M6x20 12.9 Gleitmo 603+Geomet 500 (3 pcs) Tightening torque: 14 Nm xx2000001686 Check the radial sealing on the swing support (IP67, Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the swing support. Replace if damaged, as described below. xx2000002466 3 Fit the big circular plate of the axis-2 sealing as- Big circular plate of the axis-2 sembly tool to the swing support (opposite side sealing assembly tool, included in of the radial sealing) with three M4x12 screws. Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002467 Continues on next page Product manual - IRB 1300 615 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 4 Note Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. 5 Fit the new sealing into the swing support. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002468 xx2000002537 6 For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) Place the ring of the axis-2 sealing assembly tool against the sealing. Ring of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002469 xx2000002562 Continues on next page 616 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued 7 Action Note Fit the small circular plate of the axis-2 sealing assembly tool and fix with three M6x75 screws. Small circular plate of the axis-2 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002470 xx2000002471 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Refitting the swing support Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the sealing ring. Replace if damaged. Sealing ring, swing support side: 3HAC065676-001 Screw: M4x12 12.9 Lafre 2C2B/FC6.9 (16 pcs) Tightening torque: 3.8 Nm xx2000001692 Continues on next page Product manual - IRB 1300 617 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued 3 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the O-ring. Replace if damaged. O-ring on lower arm: 3HAC061327015 xx2000002518 4 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for swing support, short: 3HAC067822-001 Gasket for swing support, long: 3HAC067823-001 xx2000002520 5 Route the cable package through the swing support. Make sure that: • the air hoses are facing the SMB side in the hollow tube of axis-1 gearbox. • the cable package is out from the hole near the base rear, as circled in the figure. CAUTION xx2000001745 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001747 Continues on next page 618 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued 6 Action Note Refit the swing support. Screw: M8x40 12.9 Gleitmo 603+Geomet 500 (7 pcs) Tightening torque: 36 Nm xx2000001684 7 Apply grease to the axis-2 cable protector and slip it over the cable harness. Grease: 3HAC029132-001 Plastic cable protector, axis 2: 3HAC067816-001 xx2000001567 Refitting the axis-2 motor Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 CAUTION Do not mix the axis-2 motor used for IRB 13007/1.4 and IRB 1300-12/1.4. Always carefully check the part number attached to the motor and the robot type, and refit with the right one. 3 Axis-2 motor for IRB 1300-7/1.4: 3HAC073078-001 Axis-2 motor for IRB 1300-12/1.4: 3HAC082078-001 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. Continues on next page Product manual - IRB 1300 619 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued 4 Action Note Check the O-ring. Replace if damaged. O-ring on motor unit: 3HAC061327037 xx2000001629 5 Apply lubricating oil to the motor that has contact- Kyodo Yushi TMO150: 3HAC032140-001 ing area with the gearbox. xx2000001701 6 Orient the motor correctly and fit it into the swing. Motor orientation: orient the motor Make sure the motor is properly fit to gearbox. according to the figure below, in regard to the encircled motor connector. xx2000001630 7 Refit the screws and washers. Screw: M6x20 12.9 Gleitmo 603+Geomet 500 (4 pcs) Tightening torque: 10 Nm xx2000001626 Continues on next page 620 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Releasing the weight support for lower and upper arms Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 WARNING Personnel must not, under any circumstances, be present under the suspended load. 3 Make sure the lower and upper arms are firmly secured with the swing. 4 Remove the roundslings. Securing the cable package in the swing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Route the cable package up into the lower arm. Make sure that the the air hoses are facing outside in the axis-2 cable protector, see the figure as a guidance for the cable twisting way. xx2000001746 Continues on next page Product manual - IRB 1300 621 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued 3 Action Note Refit the cable brackets. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each bracket on cable package and 2 pcs on swing) Tightening torque: 2.6 Nm xx2100001466 xx2000001557 4 Refit the axis-2 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001556 Routing the cable package in the lower arm Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 622 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued 2 Action Note Refit the connector plate to the cable package. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001554 3 Check the axis-3 cable protector. Replace if damaged. Grease: 3HAC029132-001 Plastic cable protector, axis 3: 3HAC064693-001 Note If replaced, apply grease to the axis-3 cable protector before refitting. xx2000001568 Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 2.6 Nm xx2000001552 4 Route the cable package through the lower arm support and up into the housing. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001569 Continues on next page Product manual - IRB 1300 623 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Reconnecting the axis-2 and -3 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001551 3 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001549 4 Reconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip See the number markings on the connectors for help to find the corresponding connector. 5 Refit the connector plate to the lower arm. xx2000001550 Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001548 Continues on next page 624 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Securing the cable package in the lower arm Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the cable bracket. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs on the cable package and 2 pcs on lower arm) Tightening torque: 2.6 Nm xx2100001465 xx2000001553 Routing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Slip the axis-4 cable protector over the cable package. Plastic cable protector, axis 4: 3HAC064694-001: xx2000001570 Continues on next page Product manual - IRB 1300 625 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 3 Note Insert the cable package through the hollow tube of the axis-4 gearbox, into the extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4) and into the tubular. Make sure that: • the air hoses are facing the axis-3 gearbox side in the hollow tube of axis-4 gearbox. CAUTION xx2000001571 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Securing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the axis-4 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001546 Reconnecting the axis-4 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001545 Continues on next page 626 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 3 Note Reconnect the connectors. • FB4 • MP4 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001544 4 Route and secure the cabling with a cable strap. Note The motor cablings have another strap fixed. Pay attention to the location where the new strap to be fixed, see the figure as a guidance. CAUTION xx2000001543 Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the connector plate. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001542 Routing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 627 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 2 Note Refit the second semicircular bracket to the tubu- Screw: M4x8 12.9 Lafre lar. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001749 3 Route the cablings. • Leave the CP/CS connectors and motor connectors out from the tubular support, and Ethernet connectors and air hoses out from the process hub. • The air hoses are facing upside in the semicircular bracket. Reconnecting the air hoses and Ethernet cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Reconnect the air hoses. Note See the number markings on the air hoses for help to find the corresponding air hoses. xx2000001539 3 For robots with Ethernet cabling Access the connector from the process hub and reconnect the connector. • J1.C2 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001540 Continues on next page 628 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Reconnecting the CP/CS cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the connectors to the connector plate. xx2000001537 3 For robots with CP/CS cabling Reconnect the connectors. • J1.C1 • J1.C3 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001536 Reconnecting the axis-5 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001535 Continues on next page Product manual - IRB 1300 629 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 3 Note Reconnect the connectors. • FB5 • MP5 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001534 Reconnecting the axis-6 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001533 3 Reconnect the connectors. • FB6 • MP6 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001532 Refitting the process hub Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 630 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued 2 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for process hub: 3HAC070887-001 xx2000002512 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolts. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002513 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the process hub. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001538 Securing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 631 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 2 Note Refit the first semicircular bracket to fix the cable Screw: M4x12 12.9 Lafre package. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001748 3 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each plate) Tightening torque: 1.3 Nm xx2000001531 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001530 Refitting the covers Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 632 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 2 Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) Check the gaskets. • Gasket for tubular support cover (A) • Gasket for housing cover (B) • Gasket for lower arm support cover (C) • Gasket for swing covers (D) Replace if damaged. xx2000002498 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm support cover (C) • Swing covers (D) Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001682 Jogging the robot to oil filling position Action 1 Note Turn on the electric power to the robot. If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to Supplying power to connector R1.MP on page 66. Continues on next page Product manual - IRB 1300 633 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 2 Note Jog the robot to the specified position: • Axis 1: 0° • Axis 2: -67.5 • Axis 3: 0° • Axis 4: 0° • Axis 5: 0° • Axis 6: No significance. xx2000001519 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Refilling oil to axis-2 gearbox Action Note 1 WARNING Handling gearbox oil involves several safety risks, see Gearbox lubricants (oil or grease) on page 29. 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. Continues on next page 634 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action 3 Note Open the upper oil plug. Note The lower oil plug has to be closed; otherwise, the oil may leak before required oil amount is filled. xx2000001518 A Oil plug, opened B Oil plug, closed 4 WARNING Overfilling of gearbox lubricant can lead to internal over-pressure inside the gearbox which in turn may: • damage seals and gaskets • completely press out seals and gaskets • prevent the robot from moving freely. 5 Refill the gearbox with oil. Note Type of oil and total amount is detailed in Technical reference manual - Lubrication in gearboxes. The amount of oil to be filled depends on the amount previously being drained. CAUTION Oil filling must be slow to make sure air venting is fluent. 6 Inspect the oil level by measuring the level at the upper oil plug hole. Required oil level: within the range of 64 mm to 69 mm below the edge of the oil plug hole. CAUTION The oil level sinks when the oil fills all cavities in the gearbox. Wait until the oil stops sinking, before measuring the oil level. xx2000001580 7 Refit the oil plug. Tightening torque: 10 Nm Continues on next page Product manual - IRB 1300 635 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action Note 8 DANGER Make sure all safety requirements are met when performing the first test run. Jogging the robot to zero position Action Note 1 Turn on the electric power to the robot. If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to Supplying power to connector R1.MP on page 66. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. Continues on next page 636 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.2 Replacing the axis-2 gearbox Continued Action Note 3 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1300 637 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox 5.7.3 Replacing the axis-3 gearbox Location of the axis-3 gearbox The axis-3 gearbox is located as shown in the figure. xx2000001488 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Gear unit, axis 3 3HAC073080-001 O-ring on circular spline side, axis 3HAC061327-016 3 Note Not used with protection class IP40. Replace if damaged. Timing belt, axis 3 3HAC067040-001 Process hub, basic 3HAC073306-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Continues on next page 638 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Spare part Article number Note Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Plastic cable protector, axis 3 3HAC064693-001 Plastic cable protector, axis 4 3HAC064694-001 Lower arm support 3HAC073076-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm support, Clean Room 3HAC077813-001 Used with protection type Clean Room. Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Gasket for lower arm support 3HAC067826-001 Not used with protection class IP40. Replace if damaged. Continues on next page Product manual - IRB 1300 639 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Spare part Article number Note Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Radial sealing on lower arm 3HAC070148-005 Not used with protection class IP40. Replace if damaged. Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply - Used to release the motor brakes. Sonic tension meter - Used for measuring the timing belt tension. Special toolkit for IP67/Clean Room/Foundry Plus robots 3HAC078203-001 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. Consumable Article number Note Cable straps - Grease 3HAC029132-001 Required consumables FM 222 Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Continues on next page 640 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action Note If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Removing the gearbox Use these procedures to remove the axis-3 gearbox. Preparations before removing the axis-3 gearbox Action Note 1 Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. 2 Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 641 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Removing the covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm covers (C) xx2000001661 Loosening the cables in the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 642 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 3 Note Cut the cable straps. xx2000001530 4 Remove the connector plates. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001531 Disconnecting the axis-6 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 643 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 3 Note Disconnect the connectors. • MP6 • FB6 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001532 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001533 Disconnecting the axis-5 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 644 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 3 Note Disconnect the connectors. • MP5 • FB5 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001534 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001535 Disconnecting CP/CS cabling (if equipped) Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 For robots with CP/CS cabling Disconnect the connectors. • J1.C1 • J1.C3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001536 Continues on next page Product manual - IRB 1300 645 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 4 Note Snap loose and remove the male head of the connectors from the connector plate. xx2000001537 Separating the cable package from the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the first semicircular bracket that fixes the cable package. xx2000001748 4 Remove the second semicircular bracket from the tubular. xx2000001749 Continues on next page 646 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Removing the process hub Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws and carefully open the cover. CAUTION There is cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. xx2000001538 4 Disconnect the air hoses. xx2000001539 Continues on next page Product manual - IRB 1300 647 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 5 Note For robots with Ethernet cabling Access the connector from the process hub and disconnect the connector. • J1.C2 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001540 Tip The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Disconnecting the axis-4 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 648 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 3 Note Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001542 4 Cut the cable strap. Note The motor cablings have another strap fixed. Always cut the strap that fixes the cable package to the plate. xx2000001543 5 Disconnect the connectors. • MP4 • FB4 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001544 6 Snap loose and remove the male head of the connectors from the connector plate. xx2000001545 Separating the cable package from the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 649 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the axis-4 cable protector. xx2000001546 Disconnecting the axis-2 and -3 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate, as shown in following step. xx2000001548 Continues on next page 650 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 4 Note Cut the cable straps. xx2000001549 5 Disconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. 6 xx2000001550 Snap loose and remove the male head of the connectors from the connector plate. xx2000001551 Pulling out the cable package Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 651 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 3 Note Remove the cable bracket from the lower arm first and then from the cable package. xx2000001553 xx2100001465 4 Wrap the connectors with the masking tape. 5 Pull the cable package out to the lower arm support. Note During the routing, make sure the axis-2 motor cablings are kept visible and accessible from the lower arm support side. xx2000001662 Removing the lower arm support Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 652 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 3 Note Remove the lower arm support. Tip If the lower arm support is hard to loosen from the swing, use a plastic hammer to knock on the lower arm support lightly. xx2000001663 Removing the axis-3 timing belt Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Loosening timing belts will release axes. This means the axes can fall down. Make sure axes are well supported before loosening timing belts. 4 CAUTION The upper arms, which includes housing, extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4), tubular and tilt unit weighs 17 kg. All lifting accessories used must be sized accordingly! 5 Fit a roundsling to the upper arm to support the weight (no force). Continues on next page Product manual - IRB 1300 653 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 6 Note Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001614 7 Remove the timing belt from its groove on the motor. xx2000001615 Separating the lower arm from the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws. WARNING This releases the upper arm from the lower arm. Make sure the weight of the upper arm is properly secured. The upper arm, including housing, extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4), tubular and tilt unit, weighs 17 kg. xx2000001664 Continues on next page 654 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 4 Note Separate the lower arm from the housing. Tip If the lower arm is hard to loosen from the housing, use a plastic hammer to knock on the lower arm lightly. xx2000001665 5 Lay down the upper arm on a workbench. Make sure to support the gravity center of the upper arm. Removing the axis-3 gearbox Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing gearboxes will release axes. This means the axes can fall down. Make sure axes are well supported before removing gearboxes. 4 Remove the screws. xx2000001666 Continues on next page Product manual - IRB 1300 655 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 5 Note Pull out the gearbox. xx2000001667 Refitting the gearbox Use these procedures to refit the axis-3 gearbox. Refitting the axis-3 gearbox Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the O-ring. Replace if damaged. O-ring on circular spline side, axis 3: 3HAC061327-016 xx2000002524 3 Refit the axis-3 gearbox. xx2000001667 Continues on next page 656 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued 4 Action Note Secure with screws. Screw: M4x35 12.9 Lafre 2C2B/FC6.9 (12 pcs) Tightening torque: 4.2 Nm±3% xx2000001666 Checking the radial sealing on the lower arm (Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the lower arm. Replace if damaged, as described below. xx2000002472 Figure 5.3: 3 Fit the big circular plate of the axis-3 sealing as- Big circular plate of the axis-3 sembly tool to the lower arm (opposite side of the sealing assembly tool, included in radial sealing) with three M4x12 screws. Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002473 Continues on next page Product manual - IRB 1300 657 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action Note 4 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. 5 Fit the new sealing into the lower arm. The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002474 xx2000002537 6 Place the ring of the axis-3 sealing assembly tool Ring of the axis-3 sealing assembly tool, included in Special toolkit for against the sealing. IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002499 xx2000002562 Continues on next page 658 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued 7 Action Note Fit the small circular plate of the axis-3 sealing assembly tool against the sealing and fix with three M6x75 screws. Small circular plate of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002475 xx2000002476 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Refitting the lower arm to the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the lower arm to the housing. Screw: M4x16 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Tightening torque: 4.5 Nm±3% xx2000001664 Continues on next page Product manual - IRB 1300 659 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Checking the radial sealing on the lower arm support (IP67, Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the lower arm support. Replace if damaged, as described below. xx2000002477 3 Fit the big circular plate of the axis-3 sealing assembly tool to the lower arm support (opposite side of the radial sealing) with three M4x12 screws. Big circular plate of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002478 4 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. Continues on next page 660 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 5 Note Fit the new sealing into the lower arm support. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002479 xx2000002537 6 For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) Place the ring of the axis-3 sealing assembly tool against the sealing. Ring of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002480 xx2000002562 Continues on next page Product manual - IRB 1300 661 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued 7 Action Note Fit the small circular plate of the axis-3 sealing assembly tool and fix with three M6x75 screws. Small circular plate of the axis-3 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002481 xx2000002482 8 Screw the screws, little by little and evenly, to press the sealing into place. 9 Remove the assembly tool. 10 Check that the sealing is undamaged and properly fitted. Refitting the lower arm support Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for lower arm support: 3HAC067826-001 xx2000002521 Continues on next page 662 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued 3 Action Note Refit the lower arm support. Screw: M8x40 12.9 Gleitmo 603+Geomet 500 (7 pcs) Tightening torque: 39 Nm±3% xx2000001663 Refitting the axis-3 timing belt Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pulleys. xx2000001615 3 Move the motor to achieve proper belt tension. 4 Use a sonic tension meter to measure the timing belt tension. If the timing belt tension does not meet the requirement, loosen the motor screws and readjust. 5 Secure the motor with the screws. Used belt: 73.4-78.5 Hz New belt: 87.8-92.1 Hz Tightening torque: 3.3 Nm xx2000001614 6 Release the support to the upper arm. Continues on next page Product manual - IRB 1300 663 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Routing the cable package in the lower arm Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the connector plate to the cable package. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001554 3 Check the axis-3 cable protector. Replace if damaged. Grease: 3HAC029132-001 Plastic cable protector, axis 3: 3HAC064693-001 Note If replaced, apply grease to the axis-3 cable protector before refitting. xx2000001568 Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 2.6 Nm xx2000001552 Continues on next page 664 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 4 Note Route the cable package through the lower arm support and up into the housing. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx2000001569 Reconnecting the axis-2 and -3 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001551 3 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001549 Continues on next page Product manual - IRB 1300 665 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 4 Note Reconnect the connectors. • FB2 • MP2 • FB3 • MP3 Tip See the number markings on the connectors for help to find the corresponding connector. 5 Refit the connector plate to the lower arm. xx2000001550 Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001548 Securing the cable package in the lower arm Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 666 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued 2 Action Note Refit the cable bracket. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs on the cable package and 2 pcs on lower arm) Tightening torque: 2.6 Nm xx2100001465 xx2000001553 Routing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Slip the axis-4 cable protector over the cable package. Plastic cable protector, axis 4: 3HAC064694-001: xx2000001570 Continues on next page Product manual - IRB 1300 667 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 3 Note Insert the cable package through the hollow tube of the axis-4 gearbox, into the extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4) and into the tubular. Make sure that: • the air hoses are facing the axis-3 gearbox side in the hollow tube of axis-4 gearbox. CAUTION xx2000001571 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Securing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the axis-4 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001546 Reconnecting the axis-4 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001545 Continues on next page 668 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 3 Note Reconnect the connectors. • FB4 • MP4 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001544 4 Route and secure the cabling with a cable strap. Note The motor cablings have another strap fixed. Pay attention to the location where the new strap to be fixed, see the figure as a guidance. CAUTION xx2000001543 Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the connector plate. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001542 Routing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 669 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 2 Note Refit the second semicircular bracket to the tubu- Screw: M4x8 12.9 Lafre lar. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001749 3 Route the cablings. • Leave the CP/CS connectors and motor connectors out from the tubular support, and Ethernet connectors and air hoses out from the process hub. • The air hoses are facing upside in the semicircular bracket. Reconnecting the air hoses and Ethernet cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Reconnect the air hoses. Note See the number markings on the air hoses for help to find the corresponding air hoses. xx2000001539 3 For robots with Ethernet cabling Access the connector from the process hub and reconnect the connector. • J1.C2 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001540 Continues on next page 670 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Reconnecting the CP/CS cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the connectors to the connector plate. xx2000001537 3 For robots with CP/CS cabling Reconnect the connectors. • J1.C1 • J1.C3 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001536 Reconnecting the axis-5 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001535 Continues on next page Product manual - IRB 1300 671 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 3 Note Reconnect the connectors. • FB5 • MP5 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001534 Reconnecting the axis-6 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001533 3 Reconnect the connectors. • FB6 • MP6 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001532 Refitting the process hub Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 672 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued 2 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for process hub: 3HAC070887-001 xx2000002512 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolts. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002513 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the process hub. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001538 Securing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 673 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 2 Note Refit the first semicircular bracket to fix the cable Screw: M4x12 12.9 Lafre package. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001748 3 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each plate) Tightening torque: 1.3 Nm xx2000001531 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001530 Refitting the covers Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 674 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.3 Replacing the axis-3 gearbox Continued Action 2 Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) Check the gaskets. • Gasket for tubular support cover (A) • Gasket for housing cover (B) • Gasket for lower arm covers (C) Replace if damaged. xx2000002502 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm covers (C) Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001661 Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. 3 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 1300 675 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox 5.7.4 Replacing the axis-4 gearbox Location of the axis-4 gearbox The axis-4 gearbox is located as shown in the figure. xx2000001489 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 1300 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Gear unit, axis 4 3HAC073084-001 Note O-ring on circular spline side, axis 3HAC061327-021 4 Not used with protection class IP40. Replace if damaged. O-ring on flexible spline side, axis 3HAC061327-017 4 Not used with protection class IP40. Replace if damaged. Timing belt, axis 4 3HAC065806-001 Mechanical stop, axis 4, flange 3HAC065805-001 Replace if damaged. Mechanical stop, axis 4, slider 3HAC065804-001 Replace if damaged. Continues on next page 676 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Spare part Article number Note Process hub, basic 3HAC073306-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073307-001 without Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub (CP/CS and air hose, 3HAC073308-001 with Ethernet) Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Process hub, basic, Clean Room 3HAC077836-001 Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077837-001 and air hose, without Ethernet) Used with protection type Clean Room. Process hub, Clean Room (CP/CS 3HAC077838-001 and air hose, with Ethernet) Used with protection type Clean Room. Plastic cable protector, axis 3 3HAC064693-001 Plastic cable protector, axis 4 3HAC064694-001 Tubular cover 3HAC073094-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Housing cover 3HAC073093-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Lower arm cover 3HAC073092-001 Used with protection classes IP40 and IP67. Used with protection type Foundry Plus. Tubular cover, Clean Room 3HAC077823-001 Used with protection type Clean Room. Housing cover, Clean Room 3HAC077822-001 Used with protection type Clean Room. Lower arm cover, Clean Room 3HAC077821-001 Used with protection type Clean Room. Gasket for process hub 3HAC070887-001 Not used with protection class IP40. Replace if damaged. Gasket for tubular cover 3HAC067834-001 Not used with protection class IP40. Replace if damaged. Gasket for housing cover 3HAC067833-001 Not used with protection class IP40. Replace if damaged. Continues on next page Product manual - IRB 1300 677 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Spare part Article number Note Gasket for lower arm cover 3HAC067832-001 Not used with protection class IP40. Replace if damaged. Seal bolt 3HAC032050-001 Not used with protection class IP40. Replace if damaged. Radial sealing on housing 3HAC070148-006 Used with protection types Clean Room and Foundry Plus. Replace if damaged. Plug screw 3HAC078352-001 Not used with protection type Clean Room. Replace if damaged. Plug screw, Clean Room 3HAC078351-001 Used with protection type Clean Room. Replace if damaged. Rubber sealing washer 3HAC075325-001 Used with protection type Clean Room. Replace if damaged. Flange socket head screw with glue 3HAB3413-412 M4x12 12.9 Lafre 2C2B/FC6.9+PrO-COat111, with NYPLAS glue Equipment Article number Note Standard toolkit - Content is defined in section Standard toolkit on page 759. Required tools and equipment Calibration toolbox, Axis Calibra- 3HAC074119-001 tion Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. 24 VDC power supply Used to release the motor brakes. - Tension adjustment tool for axis-4 timing belt Included in special toolkit 3HAC076396-001. Dynamometer - Used for measuring the timing belt tension. Special toolkit for IP67/Clean Room/Foundry Plus robots 3HAC078203-001 Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. Consumable Article number Note Cable straps - Grease 3HAC029132-001 Required consumables FM 222 Continues on next page 678 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Deciding calibration routine Decide which calibration routine to be used, based on the information in the table. Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table. Action 1 Note Decide which calibration routine to use for calibrating the robot. • Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot. • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. If the robot is to be calibrated with reference calibration: Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot. If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible. Note Calibrating axis 6 always requires tools to be removed from the mounting flange (also for reference calibration) since the mounting flange is used for installation of the calibration tool. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. Creating new values requires possibility to move the robot. Read more about reference calibration for Axis Calibration in Reference calibration routine on page 722. If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Removing the gearbox Use these procedures to remove the axis-4 gearbox. Preparations before removing the axis-4 gearbox Action 1 Note Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure. Continues on next page Product manual - IRB 1300 679 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 2 Note Jog all axes to zero position. xx2000001520 3 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. 4 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Removing the covers Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 680 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 3 Note Remove the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm support cover (C) xx2000001668 Loosening the cables in the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Cut the cable straps. xx2000001530 4 Remove the connector plates. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001531 Continues on next page Product manual - IRB 1300 681 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Disconnecting the axis-6 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP6 • FB6 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001532 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001533 Disconnecting the axis-5 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page 682 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Disconnect the connectors. • MP5 • FB5 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001534 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001535 Disconnecting CP/CS cabling (if equipped) Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 683 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 3 Note For robots with CP/CS cabling Disconnect the connectors. • J1.C1 • J1.C3 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001536 4 Snap loose and remove the male head of the connectors from the connector plate. xx2000001537 Separating the cable package from the tubular Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the first semicircular bracket that fixes the cable package. xx2000001748 Continues on next page 684 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 4 Note Remove the second semicircular bracket from the tubular. xx2000001749 Removing the process hub Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the screws and carefully open the cover. CAUTION There is cabling attached to the cover. The cover cannot be removed completely until the connectors are removed. xx2000001538 4 Disconnect the air hoses. xx2000001539 Continues on next page Product manual - IRB 1300 685 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 5 Note For robots with Ethernet cabling Access the connector from the process hub and disconnect the connector. • J1.C2 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001540 Tip The connector clip has to be pressed (1) and pushed forward (2) to separate the J2.C2 (for Ethernet cabling). xx1800002943 Disconnecting the axis-4 motor connectors Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page 686 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 3 Note Remove the connector plate. CAUTION Be aware of the cablings that are attached to the connector plate! The connector plate cannot be removed completely until the connectors are remove from the plate. xx2000001542 4 Cut the cable strap. Note The motor cablings have another strap fixed. Always cut the strap that fixes the cable package to the plate. xx2000001543 5 Disconnect the connectors. • MP4 • FB4 Tip Take photos of the connector and cable position before disconnecting them, to have as a reference when reconnecting. xx2000001544 6 Snap loose and remove the male head of the connectors from the connector plate. xx2000001545 Separating the cable package from the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. Continues on next page Product manual - IRB 1300 687 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action Note 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Remove the axis-4 cable protector. xx2000001546 Pulling out the cable package Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Wrap the connectors with the masking tape. 4 Pull the cable package out to the lower arm support. xx2000001662 Continues on next page 688 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Removing the axis-4 motor Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing motors will release axes. This means the axes can fall down. Make sure axes are well supported before removing motors. 4 Loosen the screws and move the motor slightly to slacken the timing belt. xx2000001604 5 Remove the timing belt from its groove on the motor. 6 Remove the screws and washers. xx2000001605 Continues on next page Product manual - IRB 1300 689 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 7 Note Carefully lift out the motor. xx2000001669 8 Remove the timing belt. xx2000001670 Separating the housing Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 Support the weight of the extender unit (only for IRB 1300-7/1.4), tubular and tilt unit, and remove the screws. xx2000001671 Continues on next page 690 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 4 Note Valid for IRB 1300-11/0.9 and IRB 1300-10/1.15 Separate the tubular from the housing. xx2000001721 5 Valid for IRB 1300-7/1.4 and IRB 1300-12/1.4 Separate the extender unit from the housing. xx2000001672 Removing the axis-4 mechanical stops Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. Continues on next page Product manual - IRB 1300 691 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 3 Note Remove the axis-4 mechanical stop flange. CAUTION The axis-4 mechanical stop slider is accessible from the housing. Put it aside for later refitting. xx2000001673 xx2000001674 Removing the axis-4 gearbox Action Note 1 DANGER Make sure that all supplies for electrical power, hydraulic pressure, and air pressure are turned off. 2 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts of the robot! See Cut the paint or surface on the robot before replacing parts on page 145. 3 CAUTION Removing gearboxes will release axes. This means the axes can fall down. Make sure axes are well supported before removing gearboxes. Continues on next page 692 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 4 Note Remove the screws. xx2000001675 5 Pull out the gearbox. xx2000001676 Refitting the gearbox Use these procedures to refit the axis-4 gearbox. Refitting the axis-4 gearbox Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the o-rings. Replace if damaged. O-ring on circular spline side, axis 4: 3HAC061327-021 O-ring on flexible spline side, axis 4: 3HAC061327-017 xx2000002525 Continues on next page Product manual - IRB 1300 693 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 3 Note Refit the axis-4 gearbox. xx2000001676 4 Make sure that the screws on the gearbox are properly fitted into the notches on the extender unit/tubular. xx2000001720 Valid for IRB 1300-11/0.9 and IRB 1300-10/1.15 xx2000001719 Valid for IRB 1300-7/1.4 and IRB 1300-12/1.4 xx2000001679 Continues on next page 694 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued 5 Action Note Secure with screws. Screw: M3x35 12.9 Lafre 2C2B/FC6.9 (12 pcs) Tightening torque: 1.9 Nm xx2000001675 Refitting the axis-4 mechanical stop flange Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the axis-4 mechanical stop flange to the gearbox. xx2000001673 Continues on next page Product manual - IRB 1300 695 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 3 Note Make sure that : • the block on the mechanical stop flange is towards the upper side (process hub side). • the notches on the extender unit/tubular and the mechanical stop flange are aligned. xx2000001678 Valid for IRB 1300-11/0.9 and IRB 1300-10/1.15 xx2000001718 Valid for IRB 1300-7/1.4 and IRB 1300-12/1.4 xx2000001677 Check the radial sealing on the housing (IP67, Clean Room and Foundry Plus) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check the radial sealing on the housing. Replace if damaged, as described below. xx2000002483 Continues on next page 696 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued 3 Action Note Fit the lug plate of the axis-4 sealing assembly tool into the housing with three M4x10 screws. Lug plate of the axis-4 sealing assembly tool, included in Special toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). Note Pay attention to the location of the lugs. xx2000002484 xx2000002485 4 Apply a little grease to the sealing lip when repla- Grease: 3HAC029132-001 cing the radial sealing and wipe clean after the replacement. Note For Clean Room robots, make sure no grease is applied to the sealing grooves. 5 Fit the new sealing into the housing. For robots with protection type Clean Room (option 3351-4) The sealing lip as pointed in the following figure is facing the inner side of the robot. For robots with protection class IP67 (option 3350-670) For robots with protection type Foundry Plus (option 3352-10) The sealing lip as pointed in the following figure is facing the outer side of the robot. xx2000002486 xx2000002537 Continues on next page Product manual - IRB 1300 697 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 6 Note Fit the circular plate of the axis-4 sealing assembly Circular plate of the axis-4 sealing tool against the sealing and fix with three M6x85 assembly tool, included in Special screws. toolkit for IP67/Clean Room/Foundry Plus robots (3HAC078203-001). xx2000002487 xx2000002488 7 Screw the screws, little by little and evenly, to press the sealing into place. 8 Remove the assembly tool. 9 Check that the sealing is undamaged and properly fitted. Refitting the axis-4 mechanical stop slider Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Place the axis-4 mechanical stop slider in the housing. xx2000001732 Continues on next page 698 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Refitting the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 For robots with protection class IP67 (option O-ring on tubular: 3HAC0613273350-670) 018 For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Valid for IRB 1300-11/0.9 and IRB 1300-10/1.15 Check the O-ring. Replace if damaged. xx2000002519 3 Valid for IRB 1300-11/0.9 and IRB 1300-10/1.15 Refit the tubular to the housing. xx2000001721 4 Valid for IRB 1300-7/1.4 and IRB 1300-12/1.4 Refit the extender unit to the housing. xx2000001672 5 Refit the screws. Flange socket head screw with glue: 3HAB3413-412, M4x12 12.9 Lafre 2C2B/FC6.9+PrO-COat111, with NYPLAS glue (14 pcs) Tightening torque: 3.3 Nm xx2000001671 Continues on next page Product manual - IRB 1300 699 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Refitting the axis-4 motor Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Check that: • all assembly surfaces are clean and without damages • the motor is clean and undamaged. 3 Install the timing belt to the gearbox pulley and verify that the belt runs correctly in the grooves of the pulley. xx2000001670 4 Orient the motor correctly and fit it into the hous- Motor orientation: orient the motor ing. according to the figure below, in regard to the encircled motor connector. Note Make sure the motor flange does not press on the timing belt. xx2000001607 5 Refit the motor and verify that the timing belt runs correctly in the groove of the motor pulley. xx2000001680 Continues on next page 700 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued 6 Action Note Refit the screws and washers. Screw: M4x16 12.9 Lafre 2C2B/FC6.9 (3 pcs) Note Do not tighten the screws yet. xx2000001605 Adjusting the axis-4 timing belt tension Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Remove the screw below the housing. xx2000001609 3 Fit the tension adjustment tool for axis-4 timing belt to the screw hole. Tension adjustment tool for axis-4 timing belt. Included in special toolkit 3HAC076396-001. xx2000001610 Continues on next page Product manual - IRB 1300 701 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 4 Note Use a handheld dynamometer hooking to the tool. xx2000001611 5 Pull the dynamometer to make the tension falling Used belt: 16.7-19.1 N in the allowed force range. New belt:23.9-26.2 N Note Pay attention to the force application direction. xx2000001612 6 Secure the motor with the screws. Tightening torque: 3.3 Nm±3% xx2000001604 Continues on next page 702 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued 7 Action Note Remove the tool and refit the plug screw. For robots with protection type Clean Room (option 3351-4) Refit the plug screw with the rubber washer. Tightening torque: 3 Nm For robots NOT with protection type Clean Room Plug screw: 3HAC078352-001 xx2000001609 For robots with protection type Clean Room (option 3351-4) Plug screw, Clean Room: 3HAC078351-001 Rubber sealing washer: 3HAC075325-001 xx2000002496 Securing the cable package in the lower arm Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 703 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued 2 Action Note Check the axis-3 cable protector. Replace if damaged. Grease: 3HAC029132-001 Plastic cable protector, axis 3: 3HAC064693-001 Note If replaced, apply grease to the axis-3 cable protector before refitting. xx2000001568 Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 2.6 Nm xx2000001552 3 Route the cable package through the lower arm support and up into the housing. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Routing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Slip the axis-4 cable protector over the cable package. Plastic cable protector, axis 4: 3HAC064694-001: xx2000001570 Continues on next page 704 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 3 Note Insert the cable package through the hollow tube of the axis-4 gearbox, into the extender unit (only for IRB 1300-7/1.4 and IRB 1300-12/1.4) and into the tubular. Make sure that: • the air hoses are facing the axis-3 gearbox side in the hollow tube of axis-4 gearbox. CAUTION xx2000001571 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Securing the cable package in the housing Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Refit the axis-4 cable protector. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001546 Reconnecting the axis-4 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001545 Continues on next page Product manual - IRB 1300 705 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 3 Note Reconnect the connectors. • FB4 • MP4 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001544 4 Route and secure the cabling with a cable strap. Note The motor cablings have another strap fixed. Pay attention to the location where the new strap to be fixed, see the figure as a guidance. CAUTION xx2000001543 Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the connector plate. Screw: M4x8 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001542 Routing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 706 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 2 Note Refit the second semicircular bracket to the tubu- Screw: M4x8 12.9 Lafre lar. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001749 3 Route the cablings. • Leave the CP/CS connectors and motor connectors out from the tubular support, and Ethernet connectors and air hoses out from the process hub. • The air hoses are facing upside in the semicircular bracket. Reconnecting the air hoses and Ethernet cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Reconnect the air hoses. Note See the number markings on the air hoses for help to find the corresponding air hoses. xx2000001539 3 For robots with Ethernet cabling Access the connector from the process hub and reconnect the connector. • J1.C2 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001540 Continues on next page Product manual - IRB 1300 707 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Reconnecting the CP/CS cabling (if equipped) Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the connectors to the connector plate. xx2000001537 3 For robots with CP/CS cabling Reconnect the connectors. • J1.C1 • J1.C3 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001536 Reconnecting the axis-5 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001535 Continues on next page 708 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 3 Note Reconnect the connectors. • FB5 • MP5 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001534 Reconnecting the axis-6 motor connectors Action Note 1 For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. 2 Insert the male header of the motor connectors to the connector plate. xx2000001533 3 Reconnect the connectors. • FB6 • MP6 Tip See the number markings on the connectors for help to find the corresponding connector. xx2000001532 Refitting the process hub Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 709 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued 2 Action Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the gasket. Replace if damaged. Gasket for process hub: 3HAC070887-001 xx2000002512 3 For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) For robots with protection type Foundry Plus (option 3352-10) Check the seal bolts. Replace if damaged. Seal bolt: 3HAC032050-001 xx2000002513 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. 5 Refit the process hub. Screw: M4x10 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 2.6 Nm xx2000001538 Securing the cable package in the tubular Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page 710 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 2 Note Refit the first semicircular bracket to fix the cable Screw: M4x12 12.9 Lafre package. 2C2B/FC6.9 (2 pcs) Tightening torque: 2.6 Nm xx2000001748 3 Refit the connector plate. Screw: M3x8 12.9 Lafre 2C2B/FC6.9 (2 pcs for each plate) Tightening torque: 1.3 Nm xx2000001531 4 Route and secure the cabling with cable straps. CAUTION Correct cable routing is highly important. If the cables are routed and secured incorrectly the cables can be damaged. xx2000001530 Refitting the covers Action 1 Note For robots with protection type Clean Room: Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free. Continues on next page Product manual - IRB 1300 711 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 5 Repair 5.7.4 Replacing the axis-4 gearbox Continued Action 2 Note For robots with protection class IP67 (option 3350-670) For robots with protection type Clean Room (option 3351-4) Check the gaskets. • Gasket for tubular support cover (A) • Gasket for housing cover (B) • Gasket for lower arm covers (C) Replace if damaged. xx2000002506 3 Apply grease to the cable package, cover all moving area of the package. Grease: 3HAC029132-001 4 Apply grease to the covers that have contacting Grease: 3HAC029132-001 area with the cable package. 5 Refit the covers. • Tubular support cover (A) • Housing cover (B) • Lower arm covers (C) Screw: M4x10 12.9 Lafre 2C2B/FC6.9 Tightening torque: 2.6 Nm xx2000001668 Concluding procedure Action 1 Note 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 145. Note After all repair work, wipe the Clean Room robot free from particles with spirit on a lint free cloth. 2 Recalibrate the robot. Calibration is detailed in section Calibration on page 713. 3 DANGER Make sure all safety requirements are met when performing the first test run. 712 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.1.1 Introduction and calibration terminology 6 Calibration 6.1 Introduction to calibration 6.1.1 Introduction and calibration terminology Calibration information This chapter includes general information about the recommended calibration methods and also the detailed procedures for updating the revolution counters, checking the calibration position etc. Detailed instructions of how to perform Axis Calibration are given on the FlexPendant during the calibration procedure. To prepare calibration with Axis Calibration method, see Calibrating with Axis Calibration method on page 721. 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 position 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 recalibrate the robot back to the same position as when the reference was stored. This routine is more flexible compared to fine calibration 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. Product manual - IRB 1300 713 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.1.2 Calibration methods 6.1.2 Calibration methods Overview This section specifies the different types of calibration and the calibration methods that are supplied by ABB. Types of calibration Type of calibration Description Calibration method Standard calibration The calibrated robot is positioned at calibration Axis Calibration position. Standard calibration data is found on the SMB (serial measurement board) or EIB in the robot. Absolute accuracy Based on standard calibration, and besides CalibWare calibration (option- positioning the robot at synchronization posial) tion, the Absolute accuracy calibration also compensates for: • Mechanical tolerances in the robot structure • Deflection due to load Absolute accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot. Absolute accuracy calibration data is found on the SMB (serial measurement board) in the robot. A robot calibrated with Absolute accuracy has the option information printed on its name plate. To regain 100% Absolute accuracy performance, the robot must be recalibrated for absolute accuracy after repair or maintenance that affects the mechanical structure. Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 1300. It is the recommended method in order to achieve proper performance. The following routines are available for the Axis Calibration method: • Fine calibration • Update revolution counters • Reference calibration The calibration equipment for Axis Calibration is delivered as a toolkit. An introduction to the calibration method is given in this manual, see Calibrating with Axis Calibration method on page 721. The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant. You will be guided through the calibration procedure, step by step. Continues on next page 714 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.1.2 Calibration methods Continued CalibWare - Absolute Accuracy calibration The CalibWare tool guides through the calibration process and calculates new compensation parameters. This is further detailed in the Application manual - CalibWare Field. If a service operation is done to a robot with the option Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance. For most cases after replacements that do not include taking apart the robot structure, standard calibration is sufficient. The Absolute Accuracy option varies according to the robot mounting position. This is printed on the robot name plate for each robot. The robot must be in the correct mounting position when it is recalibrated for absolute accuracy. References Article numbers for the calibration tools are listed in the section Special tools on page 760. Product manual - IRB 1300 715 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.1.3 When to calibrate 6.1.3 When to calibrate When to calibrate The system must be calibrated if any of the following situations occur. The resolver values are changed If resolver values are changed, the robot must be re-calibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy. The resolver values will change when parts affecting the calibration position are replaced on the robot, for example motors or parts of the transmission. The revolution counter memory is lost If the revolution counter memory is lost, the counters must be updated. See Updating revolution counters on page 719. This will occur when: • The battery is discharged • A resolver error occurs • The signal between a resolver and measurement board is interrupted • A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and controller are connected at the first installation. The robot is rebuilt If the robot is rebuilt, for example, after a crash or when the reach ability of a robot is changed, it needs to be re-calibrated for new resolver values. If the robot has absolute accuracy calibration, it needs to be calibrated for new absolute accuracy. Robot is not floor mounted The original calibration data delivered with the robot is generated when the robot is floor mounted. If the robot is not floor mounted, then the robot accuracy could be affected. The robot needs to be calibrated after it is mounted. 716 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.2.1 Synchronization marks and synchronization position for axes 6.2 Synchronization marks and axis movement directions 6.2.1 Synchronization marks and synchronization position for axes Introduction This section shows the position of the synchronization marks and the synchronization position for each axis. Synchronization marks, IRB 1300 6 3 5 2 4 1 xx2000000404 Product manual - IRB 1300 717 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.2.2 Calibration movement directions for all axes 6.2.2 Calibration movement directions for all axes Overview When calibrating, the axis must consistently be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears and so on. Positive directions are shown in the graphic below. Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below. Manual movement directions xx2000000405 718 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.3.1 Updating revolution counters on OmniCore robots 6.3 Updating revolution counters 6.3.1 Updating revolution counters on OmniCore robots Introduction This section describes how to do a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant. Step 1 - Manually running the manipulator to the synchronization position Use this procedure to manually run the manipulator to the synchronization position. Action Note 1 Select axis-by-axis motion mode. 2 Jog the manipulator to align the synchron- See Synchronization marks and synchronization marks. ization position for axes on page 717. 3 When all axes are positioned, update the Step 2 - Updating the revolution counter revolution counter. with the FlexPendant on page 719. Step 2 - Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant (OmniCore). Action 1 On the start screen, tap Calibrate. 2 Select Calibration from the menu. The Mechanical Units page displays a list of available mechanical units. Note This step is required only if you are not already in the Mechanical Unit page when you open Calibrate. Note The Mechanical Unit page is displayed only if there are more than one mechanical unit available. Otherwise, the calibration summary page for the available mechanical unit is displayed. 3 Select the mechanical unit for which revolution counter need to be updated. 4 The calibration summary page for the selected mechanical unit is displayed. Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. 5 Tap Calibration Methods on the right pane. The calibration options are displayed. 6 Tap Revolution Counters. 7 In the Selection column select the axes for which revolution counters need to be updated. Continues on next page Product manual - IRB 1300 719 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.3.1 Updating revolution counters on OmniCore robots Continued Action 8 Tap Update. A dialog box is displayed, warning that the updating operation cannot be undone: • Tap Update to proceed with updating the revolution counters. • Tap Cancel to cancel updating the revolution counters. Tapping Update and a confirmation window is displayed. 9 Tap OK. The revolution counter for the selected axes is updated. 10 CAUTION If a revolution counter is incorrectly updated, it will cause incorrect manipulator positioning, which in turn may cause damage or injury! Check the synchronization position very carefully after each update. See Checking the synchronization position on page 738. 720 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.1 Description of Axis Calibration 6.4 Calibrating with Axis Calibration method 6.4.1 Description of Axis Calibration Instructions for Axis Calibration procedure given on the FlexPendant The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant. You will be guided through the calibration procedure, step by step. This manual contains a brief description of the method, additional information to the information given on the FlexPendant, article number for the tools and images of where to fit the calibration tools on the robot. Overview of the Axis Calibration procedure The Axis Calibration procedure applies to all axes, and is performed on one axis at the time. The robot axes are both manually and automatically moved into position, as instructed on the FlexPendant. A fixed calibration pin/bushing is installed on each robot axis at delivery. For axis 6 calibration there is one bushing on the wrist and one mounting hole on the tool flange. The Axis Calibration procedure described roughly: 1 A removable calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration, according to instructions on the FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place. 2 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. Continues on next page Product manual - IRB 1300 721 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.1 Description of Axis Calibration Continued 3 The axis position is stored in RobotWare with an active choice from the operator. Routines in the calibration procedure The following routines are available in the Axis Calibration procedure, given at the beginning of the procedure on the FlexPendant. Fine calibration routine Choose this routine to calibrate the robot when there are no tools, process cabling or equipment fitted to the robot. Reference calibration routine Choose this routine to create reference values and to calibrate the robot when the robot is dressed with tools, process cabling or other equipment. Also choose this routine if the robot is wall mounted or suspended. 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. If calibrating the robot with reference calibration there must be reference values created before repair is made to the robot, if values are not already available. Creating new values requires possibility to move the robot. The reference values contain positions of all axes, torque of axes and technical data about the tool installed. A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc. Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values. When reference calibration is performed, the robot is restored to the status given by the reference values. Update revolution counters Choose this routine to make a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant. Validation In the mentioned routines, it is also possible to validate the calibration data. Position of robot axes The robot axes should be positioned close to 0 degrees before commencing the calibration program. The axis chosen for calibration is then automatically run by the calibration program to its exact calibration position during the calibration procedure. It is possible to position some of the other axes in positions different from 0 degrees. Information about which axes are allowed to be jogged is given on the FlexPendant. Continues on next page 722 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.1 Description of Axis Calibration Continued These axes are marked with Unrestricted in the FlexPendant window. Also the following table shows the dependencies between the axes. Requirements for axis positioning during calibration Axis to calibrate Required Axis 1 position of axis Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Axis 1 - * * * * * Axis 2 0 - 0 * * * Axis 3 0 0 - * * * Axis 4 * * * - * * Axis 5 * * * * - X Axis 6 * * * * * - - Axis to be calibrated * Unrestricted. Axis is allowed to be jogged to other position than 0 degrees. 0 Axis must be put in position 0 degrees. X Special requirement System containing SafeMove SafeMove will lose its synchronization to the controller if a new calibration is done. New calibration values have to be downloaded to SafeMove, and a new SafeMove calibration has to be done. Make sure that the user rights admit to change the safety settings and to synchronize SafeMove. How to calibrate a suspended or wall mounted robot The IRB 1300 is fine calibrated floor standing in factory, prior to shipping. To calibrate a suspended or wall mounted robot, reference calibration could be used. Reference values for a suspended or a wall mounted robot must be created with the robot mounted at its working position, not standing on a floor. To calibrate a suspended or wall mounted robot with the fine calibration routine, the robot must first be taken down and mounted standing on the floor. Product manual - IRB 1300 723 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.2 Calibration tools for Axis Calibration 6.4.2 Calibration tools for Axis Calibration Calibration tool set The calibration tools used for Axis Calibration are designed to meet requirements for calibration performance, durability and safety in case of accidental damage. The calibration tool will eventually break from fatigue after longer period of use and then needs to be replaced. There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number Calibration toolbox, Ax- 3HAC074119-001 is Calibration Note Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. Examining the calibration tool Check prior to usage Before using the calibration tool, make sure that the tube insert, the plastic protection and the steel spring ring are present. WARNING If any part is missing or damaged, the tool must be replaced immediately. xx1500001914 A Tube insert B Plastic protection C Steel spring ring Continues on next page 724 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.2 Calibration tools for Axis Calibration Continued Periodic check of the calibration tool If including the calibration tool in a local periodic check system, the following measures should be checked. • Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on calibration tool size). • Straightness within 0.005 mm. xx1500000951 A Outer diameter Periodic check of the calibration tool for the tool flange (3HAC058238-001) If including the tool flange calibration tool in a local periodic check system, the following measures should be checked. • Outer diameter within Ø5g5 mm. • Straightness within 0.005 mm. . xx1600001142 A Outer diameter Identifying the calibrating tools It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Continues on next page Product manual - IRB 1300 725 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.2 Calibration tools for Axis Calibration Continued Action 1 Note It is possible to use any RFID solution, with the correct dimensions. ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices (13.56 Mhz) according to ISO 14443 or ISO 15693. Note The maximum dimensions on the RFID chip must not exceed Ø7.9 mm x 8.0 mm, Ø5.9 mm x 8.0 mm or Ø3.9 mm x 8.0 mm (depending on calibration tool size). 2 There is a cavity on one end of the calibration tool in which the RFID chip can be installed. Install the RFID chip according to supplier instructions. Install the chip in flush with the tool end. 726 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.3 Installation locations for the calibration tools 6.4.3 Installation locations for the calibration tools Location of fixed calibration items This section shows how the robot is equipped with items for installation of calibration tools for Axis Calibration (fixed calibration pins and/or bushings). Installed calibration tools are not shown. A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows. If there is not enough space on an axis to install a fixed calibration pin, the axis is equipped with two bushings instead, for installation of two calibration tools when calibration is carried out. This is shown in the figure. For axis 6 there is only one bushing, the second calibration tool is installed at the mounting flange of the turning disk. xx2000001310 Continues on next page Product manual - IRB 1300 727 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.3 Installation locations for the calibration tools Continued xx2000001311 xx2000001312 Continues on next page 728 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.3 Installation locations for the calibration tools Continued Spare parts When calibration is not being performed, a protective cover and an o-ring should always be installed on the fixed calibration pin as well as a protective plug, included a sealing, in the bushing. Replace damaged parts with new. Spare part Article number Note Protective plug for 10-mm bushing 3HAC053237-003 Replace if damaged or missing. Protective plug for 12-mm bushing 3HAC053237-002 Replace if damaged or missing. Calibration pin cover, 10 mm 3HAC056253-003 Replace if damaged or missing. Calibration pin cover, 14 mm 3HAC056253-002 Replace if damaged or missing. O-ring on calibration pin 3HAC061327-022 Replace if damaged or missing. O-ring on calibration pin 3HAC061327-011 Replace if damaged or missing. Rubber sealing washer with 3HAC077381-001 10-mm protective cover Used with protection type Clean Room. Replace if damaged or missing. Rubber sealing washer with 3HAC075324-001 12-mm protective cover Used with protection type Clean Room. Replace if damaged or missing. Rubber sealing washer for 10- 3HAC075325-001 mm calibration pin cover Used with protection type Clean Room. Replace if damaged or missing. Rubber sealing washer for 14- 3HAC075323-001 mm calibration pin cover Used with protection type Clean Room. Replace if damaged or missing. Product manual - IRB 1300 729 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.4 Axis Calibration - Running the calibration procedure 6.4.4 Axis Calibration - Running the calibration procedure Required tools The calibration tools used for Axis Calibration are designed to meet requirements for calibration performance, durability and safety in case of accidental damage. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc. Article number Calibration toolbox, Axis Cal- 3HAC074119-001 ibration Note Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. Required consumables Consumable Article number Clean cloth - Note Spare parts Spare part Article number Note Protective plug for 10-mm bushing 3HAC053237-003 Replace if damaged or missing. Protective plug for 12-mm bushing 3HAC053237-002 Replace if damaged or missing. Calibration pin cover, 10 mm 3HAC056253-003 Replace if damaged or missing. Calibration pin cover, 14 mm 3HAC056253-002 Replace if damaged or missing. O-ring on calibration pin 3HAC061327-022 Replace if damaged or missing. O-ring on calibration pin 3HAC061327-011 Replace if damaged or missing. Rubber sealing washer with 3HAC077381-001 10-mm protective cover Used with protection type Clean Room. Replace if damaged or missing. Rubber sealing washer with 3HAC075324-001 12-mm protective cover Used with protection type Clean Room. Replace if damaged or missing. Rubber sealing washer for 10- 3HAC075325-001 mm calibration pin cover Used with protection type Clean Room. Replace if damaged or missing. Rubber sealing washer for 14- 3HAC075323-001 mm calibration pin cover Used with protection type Clean Room. Replace if damaged or missing. Overview of the calibration procedure on the FlexPendant The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant. You will be guided through the calibration procedure, step by step. Continues on next page 730 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.4 Axis Calibration - Running the calibration procedure Continued Use the following list to learn about the calibration procedure before running the RobotWare program on the FlexPendant. It gives you a brief overview of the calibration procedure. After the calibration method has been started 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 722. 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 protective cover from the fixed pin and the protection plug from the bushing, if any, 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 protective cover on the fixed pin and the protection plug in the bushing, if any. 9 The robot moves to verify that the calibration tool is removed. 10 Choose whether to save the calibration data or not. Calibration of the robot is not finished until the calibration data is saved, as last step of the calibration procedure. Preparation prior to calibration The calibration procedure is described in the FlexPendant while conducting it. Action Note 1 DANGER While conducting the calibration, the robot needs to be connected to power. Make sure that the robot's working area is empty, as the robot can make unpredictable movements. 2 Wipe the calibration tool clean. Use a clean cloth. Note The calibration method is exact. Dust, dirt or color flakes will affect the calibration value. Starting the calibration procedure Use this procedure to start the Axis Calibration routine on the FlexPendant. Action 1 Note Tap the calibration icon and enter the calibration main page. Continues on next page Product manual - IRB 1300 731 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.4 Axis Calibration - Running the calibration procedure Continued Action 2 Note All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. Note For RobotWare 7, the mechanical unit page is displayed only if there is more than one mechanical unit available. 3 The calibration method used at ABB factory for The FlexPendant will give all informeach axis is shown, as well as calibration method ation needed to proceed with Axis used for the robot during last field calibration. Calibration. 4 Valid for RobotWare 7 Tap Calibration Methods on the right pane and then tap Calibration. The software will automatically call for the procedure for the valid calibration method. 5 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 calibration procedure on the FlexPendant on page 730. Restarting an interrupted calibration procedure If the Axis Calibration procedure is interrupted before the calibration is finished, the RobotWare program needs to be started again. Use this procedure to take required action. Situation Action The three-position enabling device on the Press and hold the three-position enabling FlexPendant has been released during robot device and press Play. movement. 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. 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 718 Axis Calibration with SafeMove option To be able to run Axis Calibration, SafeMove needs to be unsynchronized. The Axis Calibration routine recognizes if the robot is equipped with SafeMove and will force SafeMove to unsynchronize automatically. Continues on next page 732 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.4 Axis Calibration - Running the calibration procedure Continued However, SafeMove may generate other warning messages anytime during the Axis Calibration routine. When a warning message is displayed, tap Acknowledge to confirm the unsynchronized state and continue Axis Calibration procedure. CAUTION SafeMove must be synchronized after the calibration is completed. After calibration Action Note 1 Check the o-ring on the fixed calibration pin. Replace if damaged or missing. 2 Reinstall the protective cover on the fixed calibration pin on each axis, directly after the axis has been calibrated. Replace the cover with new spare part, if missing or damaged. xx1600002102 O-ring on calibration pin: 3HAC061327-022 O-ring on calibration pin: 3HAC061327-011 Calibration pin cover, 10 mm: 3HAC056253-003 Calibration pin cover, 14 mm: 3HAC056253-002 Rubber sealing washer with 10-mm protective cover: 3HAC077381-001 Rubber sealing washer with 12-mm protective cover: 3HAC075324-001 Rubber sealing washer for 10-mm calibration pin cover: 3HAC075325001 Rubber sealing washer for 14-mm calibration pin cover: 3HAC075323001 Continues on next page Product manual - IRB 1300 733 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.4 Axis Calibration - Running the calibration procedure Continued Action 3 Note Reinstall the protective plug and sealing in the bushing on each axis, directly after the axis has been calibrated. Ensure that the sealing is not damaged. Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protective plug for 10-mm bushing: 3HAC053237-003. Protective plug for 12-mm bushing: 3HAC053237-002. 734 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.5 Reference calibration 6.4.5 Reference calibration Brief introduction to Reference Calibration Reference calibration is a faster method compared to Fine calibration, as it refers to a previously made calibration. 1 Create a backup of the current robot system. 2 Check that the active calibration offset values corresponds to the values on the silver label (on the lower arm or the base). 3 Jog the manipulator so that all axes are in zero position (ex use MoveAbsJ instruction). Check that all axis scales are aligned with calibration marks. 4 If the scales differ from calibration marks it might depend on wrong turns of the revolution counters. Make a marker line on the corresponding axis to be able to validate the result of the calibration. If more than one motor revolutions are wrong, the calibration will fail. 5 Use a verification position. This is especially recommended if all axes were not aligned with the synchronization marks (step 3). Reuse an existing position that is suitable and accurate so it can be used to validate the repair. Use a position where a deviation in axis calibration gives a big deviation in positioning. Note! Check the position after each repair in one axis. 6 Use Reference calibration to save reference values for all axes that is to be replaced. Make sure that the values are saved in RobotStudio or FTP program. The files are located in "Active system folder name/HOME/RefCalibFiles". 7 Perform the repair. 8 Make sure that the tooling and process equipment are the same as when creating the reference. Use Reference calibration to update the system with new calibration offset value for the repaired axis. 9 Check the position against the verification position (step 5). 10 Proceed with the repair of the next axis, if necessary, and repeat (step 8-9) for every axis. 11 (For system containing SafeMove) Download new calibration values to SafeMove. Use Visual SafeMove in RobotStudio. 12 (For system containing SafeMove) Synchronize SafeMove to activate SafeMove. 13 Perform test run. 14 Update the label for resolver values with new calibration values. Manual tuning of calibration offset Manual tuning of calibration offset is normally not needed, but can be useful in some situations. The requirement to do manual tuning is that there is a known accurate position, that worked accurately before the repair (step 5, see Brief introduction to Reference Calibration on page 735). Example "Adjust axis 4": 1 Create a backup. Continues on next page Product manual - IRB 1300 735 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.4.5 Reference calibration Continued 2 Run the manipulator to the verification position. (The manipulator position is now deviating from the verification position.) 3 Read and note current axis 4 value in degrees (example: 96.3 degrees). 4 Manually jog, only axis 4, so that the manipulator is correctly positioned to the verification position. 5 Read and note current axis 4 value in degrees (example: 94.2 degrees). 6 Move the manipulator to its calibration position. 7 Calculate the angle difference (ie 96.3-94.2=2.1 degrees). 8 Manually jog axis 4 the calculated angle difference (-2.1). NOTE! The direction +/- shall be the same direction as the direction used when axis 4 was manually jogged to coincide with the verification process. In the example -2.1 degrees. 9 Make a new manual fine calibration of axis 4 with axis in -2.1 degrees position. 10 Check again against the verification position. 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. 736 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.5 Verifying the calibration 6.5 Verifying the calibration Introduction Always verify the results after calibrating any robot axis to verify that all calibration positions are correct. Verifying the calibration Use this procedure to verify the calibration result. Action Note 1 Run the calibration home position program twice. See Checking the synchronDo not change the position of the robot axes after running ization position on page 738. the program! 2 Adjust the synchronization marks when the calibration is This is detailed in section done, if necessary. Synchronization marks and synchronization position for axes on page 717. 3 Write down the values on a new label and stick it on top of the calibration label. The label is located on the base. Product manual - IRB 1300 737 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 6 Calibration 6.6 Checking the synchronization position 6.6 Checking the synchronization position Introduction Check the synchronization position of the robot before beginning any programming of the robot system. This may be done: • Using a MoveAbsJ instruction with argument zero on all axes. • Using the Jog window on the FlexPendant. Using a MoveAbsJ instruction Use this procedure to create a program that runs all the robot axes to their synchronization position. Action Note 1 Tap Code. 2 Create a new program. 3 Use MoveAbsJ in the Add Instruction menu. 4 Create the following program: MoveAbsJ [[0,0,0,0,0,0], [9E9,9E9,9E9,9E9,9E9,9E9]] \NoEOffs, v1000, fine, tool0 5 Run the program in manual mode. 6 Check that the synchronization marks for the axes See Synchronization marks and align correctly. If they do not, update the revolu- synchronization position for axes on page 717 and Updating revolution tion counters. counters on page 719. Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes. Action Note 1 Tap Jog. 2 From the Mechanical unit list select a mechanical unit. 3 From the Motion mode section, select an axis-set that need to be jogged. For example, to jog axis 2, select the axis set Axis 1-3. 4 Follow the screen instruction on joystick movements to understand the direction of the axis that you want to move and move the joystick. 5 Manually run the robots axes to a position where the axis position value read on the FlexPendant, is equal to zero. 6 Check that the synchronization marks for See Synchronization marks and synchronthe axes align correctly. If they do not, up- ization position for axes on page 717 and date the revolution counters. Updating revolution counters on page 719. 738 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 7 Troubleshooting 7.1 Introduction to troubleshooting 7 Troubleshooting 7.1 Introduction to troubleshooting Introduction The product manual and the circuit diagram contains information that can be good when troubleshooting. For OmniCore, all event logs from the software can be seen on the FlexPendant, or in Technical reference manual - Event logs for RobotWare 7. Make sure to read through the section Safety on page 15 before starting. Troubleshooting strategies 1 Isolate the fault to pinpoint the cause of the problem from consequential problems. 2 Divide the fault chain in two. 3 Check communication parameters and cables. 4 Check that the software version is compatible with the hardware. Work systematically 1 Take a look around to make sure that all screws, connectors, and cables are secured, and that the robot and other parts are clean, not damaged, and correctly fitted. 2 Replace one thing at a time. 3 Do not replace units randomly. 4 Make sure that there are no loose screws, turnings, or other unexpected parts remaining after work has been performed. 5 When the work is completed, verify that the safety functions are working as intended. Keep a track of history • Make a historical fault log to keep track of problems over time. • Consult those working with the robot when the problem occurred. Basic scenarios What to look for during troubleshooting depends on when the fault occurred. Was the robot recently installed or was it recently repaired? The following table gives hints on what to look for in specific situations. The robot has recently been installed Check: • the configuration files • connectors • options and their configuration • changes in the robot working space/movements. Continues on next page Product manual - IRB 1300 739 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 7 Troubleshooting 7.1 Introduction to troubleshooting Continued The robot has recently been repaired Check: • all connections to the replaced part • power supplies • that the correct part has been fitted • the last repair documents. The robot recently had a software upgrade Check: • software versions • compatibilities between hardware and software • options and their configuration The robot has recently Check: been moved from one site • connections to another (an already • software versions working robot) 740 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 7 Troubleshooting 7.2 Oil and grease stains on motors and gearboxes 7.2 Oil and grease stains on motors and gearboxes Description The area surrounding the motor, gearbox or seal lip shows signs of oil leaks. This can be at the base, closest to the mating surface, at the furthest end of the motor at the resolver, or around the joints of the covers (closest to the edge) on the robot surface. Consequences Besides the dirty appearance, in most cases there are no serious consequences if the leaked amount of oil is very small. Possible causes The symptom can be caused by: • Leakage of rust preventives or mounting grease. This should be wiped off. • Leaking sealing between gearbox and motor. • Gearbox overfilled with oil. • Gearbox oil too hot. Recommended actions The following actions are recommended: Action Information 1 CAUTION Allow hot parts to cool down. 2 Wipe off the oil or grease, see Cleaning the IRB 1300 on page 106. Monitor the robot over time to see if new oil or grease occurs. 3 Check the gearbox oil level. 4 Too hot gearbox oil may be caused by: • Incorrect oil quality or level. • The robot work cycle runs a specific axis too hard. Investigate whether it is possible to program small "cooling periods" into the application. • Overpressure created inside gearbox. 5 Inspect all sealings and gaskets between motor and gearbox. Replace broken parts. Product manual - IRB 1300 If the oil spill is small, this step is sufficient. Robots performing certain, extremely heavy duty work cycles may be fitted with vented oil plugs. These are not fitted to normal duty robots, but can be purchased from your local ABB representative. 741 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 7 Troubleshooting 7.3 Mechanical noise or dissonance 7.3 Mechanical noise or dissonance Description Mechanical noise or dissonance that has not been observed before can indicate problems in bearings, motors, gearboxes, or similar. Be observant of changes over time. A faulty bearing often emits scraping, grinding, or clicking noises shortly before failing. Consequences Failing bearings cause the path accuracy to become inconsistent, and in severe cases, the joint can seize completely. Possible causes The symptom can be caused by: • Worn bearings. • Contaminations have entered the bearing grooves. • Loss of lubrication in bearings. • Loose heat sinks, fans, or metal parts. If the noise is emitted from a gearbox, the following can also apply: • Overheating. Recommended actions The following actions are recommended: Action Information 1 CAUTION Allow hot parts to cool down. 2 Verify that the service is done according to the maintenance schedule. 3 If a bearing is emitting the noise, determine which one and make sure that it has sufficient lubrication. 4 If possible, disassemble the joint and measure the clearance. 5 Bearings inside motors are not to be replaced individually, but the complete motor is replaced. 6 Make sure the bearings are fitted correctly. 7 Tighten the screws if a heat sink, fan, or metal sheet is loose. Continues on next page 742 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 7 Troubleshooting 7.3 Mechanical noise or dissonance Continued 8 Action Information Too hot gearbox oil may be caused by: • Incorrect oil quality or level. • The robot work cycle runs a specific axis too hard. Investigate whether it is possible to program small "cooling periods" into the application. • Overpressure created inside gearbox. Robots performing certain, extremely heavy duty work cycles may be fitted with vented oil plugs. These are not fitted to normal duty robots, but can be purchased from your local ABB representative. Product manual - IRB 1300 743 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 7 Troubleshooting 7.4 Manipulator collapses on power down 7.4 Manipulator collapses on power down Description The manipulator is able to work correctly while Motors ON is active, but when Motors OFF is active, one or more axes drops or collapses under its own weight. The holding brakes (normally one in each motor), is not able to hold the weight of the manipulator arm. Consequences For a heavy robot, the collapse can cause severe injury to personnel working in the area or severe damage to the robot and/or surrounding equipment. For a small robot, the collapse can cause injury to personnel working close to the robot or damage to the robot and/or surrounding equipment. Possible causes The symptom can be caused by: • Faulty brake. • Faulty power supply to the brake. Recommended actions The following actions are recommended: Action Information 1 Determine which motor(s) causes the robot to collapse. 2 Check the brake power supply to the col- See the circuit diagram. lapsing motor during the Motors OFF state. 3 Remove the resolver or resolver cover of the motor to see if there are any signs of oil leaks. 4 Remove the motor from the gearbox to in- If found faulty, the motor must be replaced spect it from the drive side. as a complete unit. If found faulty, the motor must be replaced as a complete unit. 744 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 7 Troubleshooting 7.5 Motor temperature too high 7.5 Motor temperature too high Description The robot stops and the motor temperature for joint arg is too high. Consequences It is not possible to continue until the motor has cooled down. The system goes to Motors Off. Possible causes The symptom can be caused by: • The values for payload and arm load are not consistent with the actual ones. • The value for ambient temperature setting in the controller is not consistent with the actual operating temperature environment. • The user program may contain too much high acceleration and deceleration of the joint. • Gravity torque or external forces for the joint can also be too high. Recommended actions The following actions are recommended: Action Information 1 CAUTION Allow hot parts to cool down. 2 Verify that the values for payload and arm load are set correctly. 3 Verify that the value for ambient temperature setting in the controller is consistent with the actual operating temperature environment. 4 Rewrite the user program to reduce the mo- The ways could be but not limited to optor utilization. timizing robot movement cycle, adjusting acc, dec as well as external force, adding wait time, and introducing alternative path/RAPID, etc. Product manual - IRB 1300 745 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. This page is intentionally left blank 8 Decommissioning 8.1 Introduction 8 Decommissioning 8.1 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. Product manual - IRB 1300 747 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 8 Decommissioning 8.2 Environmental information 8.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources. 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 Materials used in the product 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 Aluminium Base, swing, lower arm, etc Batteries, Lithium Serial measurement board Copper Cables, motors Neodymium Brakes, motors Oil, grease Gearboxes Plastic/rubber Cables, connectors, etc Steel Gearboxes, screws Continues on next page 748 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 8 Decommissioning 8.2 Environmental information Continued China RoHS symbol The following symbol shows the information to hazardous substances and the environmental protection use period of IRB 1300 according to "Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products (SJ/T 11364-2014) ". xx1900000803 Green symbol with "e" in it: The product does not contain any hazardous substances exceeding concentration limits and is a green environmentally friendly product which can be recycled. Oil and grease Where possible, arrange for oil and grease to be recycled. Dispose of via an authorized person/contractor in accordance with local regulations. Do not dispose of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration must be carried out under controlled conditions in accordance with local regulations. Also note that: • Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 1300 749 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 8 Decommissioning 8.3 Scrapping of robot 8.3 Scrapping of robot Important when scrapping the robot DANGER When a robot is disassembled while being scrapped, it is very important to remember the following before disassembling starts, in order to prevent injuries: • Always remove all batteries. If a battery is exposed to heat, for example from a blow torch, it will explode. • Always remove all oil/grease in gearboxes. If exposed to heat, for example from a blow torch, the oil/grease will catch fire. • When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. 750 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 9 Reference information 9.1 Introduction 9 Reference information 9.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 1300 751 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 9 Reference information 9.2 Applicable standards 9.2 Applicable standards General The product is compliant with ISO 10218-1:2011, Robots for industrial environments - Safety requirements - Part 1 Robots, and applicable parts in the normative references, as referred to from ISO 10218-1:2011. In case of deviation from ISO 10218-1:2011, these are listed in the declaration of incorporation. The declaration of incorporation is part of the delivery. Robot standards Standard Description ISO 9283 Manipulating industrial robots – Performance criteria and related test methods ISO 9787 Robots and robotic devices – Coordinate systems and motion nomenclatures ISO 9946 Manipulating industrial robots – Presentation of characteristics Other standards used in design Standard Description IEC 60204 Safety of machinery - Electrical equipment of machines - Part 1: General requirements, normative reference from ISO 102181 IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic standards – Immunity standard for industrial environments IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards – Emission standard for industrial environments ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems - Part 1: General principles for design, normative reference from ISO 10218-1 IEC 61340-5-1 Protection of electronic devices from electrostatic phenomena - General requirements Region specific standards and regulations Standard Description ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety requirements ANSI/ESD S20.20 Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices) EN ISO 10218-1 Robots and robotic devices — Safety requirements for industrial robots — Part 1: Robots Continues on next page 752 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 9 Reference information 9.2 Applicable standards Continued Deviations Deviation for IRB 1300 The IRB 1300 does not provide means of installing adjustable mechanical stops on axis 1. Optional features provided by SafeMove, safety-rated soft axis and space limiting can be used as risk reduction measures in specific applications. For details about SafeMove, see Application manual - Functional safety and SafeMove. Product manual - IRB 1300 753 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 9 Reference information 9.3 Unit conversion 9.3 Unit conversion Converter table Use the following table to convert units used in this manual. Quantity Units Length 1m 3.28 ft. Weight 1 kg 2.21 lb. Weight 1g 0.035 ounces Pressure 1 bar 100 kPa Force 1N 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 1L 0.264 US gal 754 39.37 in 14.5 psi Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 9 Reference information 9.4 Screw joints 9.4 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue. Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw is allowed. Using other types of screws will void any warranty and may potentially cause serious damage or injury. Gleitmo treated screws Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint. It is recommended by ABB for M6-M20 screw joints. Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one. When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used. Generally, screws are lubricated with Gleitmo 603 mixed with Geomet 500 or Geomet 702 in proportion 1:3. Geomet thickness varies according to screw dimensions, refer to the following. Dimension Lubricant Geomet thickness M6-M20 (any length except M20x60) Gleitmo 603 + Geomet 500 3-5 μm M6-M20 (any length except M20x60) Gleitmo 603 + Geomet 720 3-5 μm M20x60 Gleitmo 603 + Geomet 500 8-12 μm M20x60 Gleitmo 603 + Geomet 720 6-10 μm Screws lubricated in other ways Screws lubricated with Molykote 1000 or Molykote P1900 should only be used when specified in the repair, maintenance or installation procedure descriptions. In such cases, proceed as follows: 1 Apply lubricant to the screw thread. 2 Apply lubricant between the plain washer and screw head. 3 Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel. Continues on next page Product manual - IRB 1300 755 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 9 Reference information 9.4 Screw joints Continued Lubricant Article number Molykote 1000 (molybdenum disulphide grease) 3HAC042472-001 Molykote P1900 (molybdenum disulphide grease) 3HAC070875-001 Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the following tables. Any special torques are specified in the repair, maintenance or installation procedure descriptions. Any special torque specified overrides the standard torque! • Use the correct tightening torque for each type of screw joint. • Only use correctly calibrated torque keys. • Always tighten the joint by hand, and never use pneumatic tools. • Use the correct tightening technique, that is do not jerk. Tighten the screw in a slow, flowing motion. • Maximum allowed total deviation from the specified value is 10%! Oil-lubricated screws with slotted or cross-recess head screws The following table specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws. Note A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Oil-lubricated screws with allen head screws The following table specifies the recommended standard tightening torque for oil-lubricated screws with allen head screws. Note A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm) Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubricated 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 Continues on next page 756 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 9 Reference information 9.4 Screw joints Continued Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm) Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubricated ated M24 680 960 1150 Lubricated screws (Molykote, Gleitmo or equivalent) with allen head screws The following table specifies the recommended standard tightening torque for screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head screws. Note A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Class 10.9, lubricated i Tightening torque (Nm) Class 12.9, lubricated i M8 28 35 M10 55 70 M12 96 120 M16 235 300 M20 460 550 M24 790 950 i Lubricated with Molycote 1000, Gleitmo 603 or equivalent Product manual - IRB 1300 757 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 9 Reference information 9.5 Weight specifications 9.5 Weight specifications Definition In installation, repair, and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model. Example Following is an example of a weight specification in a procedure: Action Note CAUTION The arm weighs 25 kg. All lifting accessories used must be sized accordingly. 758 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 9 Reference information 9.6 Standard toolkit 9.6 Standard toolkit General All service (repairs, maintenance, and installation) procedures contains lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the standard toolkit and defined in the following table. This way, the tools required are the sum of the standard toolkit and any tools listed in the instruction. Contents, standard toolkit Qty Tool Rem. 1 Ring-open-end spanner 8-19 mm 1 Socket head cap 2.5-17 mm 1 Torx socket no: 20-60 1 Box spanner set 1 Torque wrench 10-100 Nm 1 Torque wrench 75-400 Nm 1 Ratchet head for torque wrench 1/2 2 Hexagon-headed screw M10x100 1 Hexagon-headed screw M16x90 1 Hex head allen wrench drill bit set M2-M8 (φ 2.5 mm - φ 10 mm) 1 Plastic mallet Product manual - IRB 1300 759 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 9 Reference information 9.7 Special tools 9.7 Special tools General All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in the section Standard toolkit on page 759, and of special tools, listed directly in the instructions and also gathered in this section. Special tools Note If the replacing procedure is not listed in the table below, only standard tools are needed for the procedure. Tools and equipment with spare part number: (These tools can be ordered from ABB) - 24 VDC power supply 3HAC074119-001 Calibration toolbox, Axis Calibration Delivered as a set of calibration tools. Required if Axis Calibration is the valid calibration method for the robot. - Sonic tension meter Used for measuring the timing belt tension. - Dynamometer Used for measuring the timing belt tension. - Oil dispenser Includes pump with outlet pipe. - Oil collecting vessel The capacity of the vessel must be sufficient to take the complete amount of oil. - Connector for quick coupling, with outlet pipe Used for draining and filling oil to axis-1 gearbox. Connector specification: G3/8 3HAC076396-001 Special toolkit Includes Axis-1 gearbox assembly cap, Axis-1 gearbox/motor sealing pressfit tool, Axis-1 gearbox/motor sealing pressfit base, Guide pin for axis-2 gearbox, Quick coupling assembly tool and Tension adjustment tool for axis-4 timing belt. 3HAC078203-001 Special toolkit for IP67/Clean Room/Foundry Plus robots Used with protection class IP67, and protection types Clean Room and Foundry Plus. Used for the press-fitting of radial sealings. Includes five sets of radial sealing assembly tool for axes 1 to 4 and axis 6. 3HAC077885-001 Lifting accessory, robot Includes lifting accessories, lifting beam and screws. 760 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. 9 Reference information 9.8 Lifting accessories and lifting instructions 9.8 Lifting accessories and lifting instructions General Many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure. The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. The instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 1300 761 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. This page is intentionally left blank 10 Spare parts 10.1 Spare part lists and illustrations 10 Spare parts 10.1 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.abb.com/myABB. Tip All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manual - IRB 1300 763 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. This page is intentionally left blank Index Index A Absolute Accuracy, calibration, 715 allergenic material, 26 aluminum disposal, 748 ambient humidity operation, 39 storage, 39 ambient temperature operation, 39 storage, 39 assembly instructions, 51 assessment of hazards and risks, 26 Axis Calibration, 721 calibration tool article number, 724, 730 examining, 724 installation position, 727 overview of method, 721 procedure on FlexPendant, 730 protective cover and protection plug, 727, 730 B axis 2, 135 cleaning, 106 climbing on robot, 29 Cold environments, 97 connecting the robot and controller, cabling, 90 copper disposal, 748 D damaged bearings, 742 dimensions robot, 75 direction of axes, 718 E environmental information, 748 equipment, robot, 75 ESD damage elimination, 50 sensitive equipment, 50 expected life, 105 extender unit replacing, 359 extra equipment, 75 F base replacing, 208 batteries disposal, 748 battery pack replacing, 122 Brake power supply, faulty, 744 brake release unit replacing, 202 brake releasing, 65 brakes testing function, 33 faulty brake, 744 fire extinguishing, 27 fitting, equipment, 75 FlexPendant jogging to calibration position, 738 MoveAbsJ instruction, 738 updating revolution counters, 719 foundation requirements, 39 G C cabinet lock, 27 cable harness replacing, 148 cable package lubricating, 119 cabling between robot and controller, 90 calibrating robot, 721 roughly, 719 calibrating robot, 721 calibration Absolute Accuracy type, 714 rough, 719 standard type, 714 verification, 737 when to calibrate, 716 calibration, Absolute Accuracy, 715 calibration manuals, 715 calibration marks, 717 calibration position jogging to, 738 scales, 717 calibration scales, 717 CalibWare, 714 carbon dioxide extinguisher, 27 changing oil axis 1, 130 gearbox oil change axis 1, 130 oil change axis 2, 135 gearbox, axis-4 replacing, 676 gearbox, axis-3 replacing, 638 gearbox, axis-2 replacing, 585 gearbox, axis-1 replacing, 578 gearboxes location of, 129 Gravity Alpha, 72 Gravity Beta, 71 grease, 29 disposal, 748 H hanging installed hanging, 26 hazard levels, 17 hazardous material, 748 height installed at a height, 26 hot gearbox oil, 741–742 hot surfaces, 29 housing replacing, 359 HRA, 26 Product manual - IRB 1300 765 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. Index humidity operation, 39 storage, 39 I information labels location, 108 inspecting information labels, 108 mechanical stops, 111 robot cabling, 110 timing belts, 115 installation equipment, 75 instructions for assembly, 51 integrator responsibility, 26 intervals for maintenance, 103 L labels robot, 19 leaking sealing, 741 lifting robot, 58 lifting accessory, 758 limitation of liability, 15 Lithium disposal, 748 loads on foundation, 37 lock and tag, 27 lower arm replacing, 294 lubricants, 29 lubricating cable package, 119 lubrication amount in gearboxes, 129 type of lubrication, 129 M maintenance intervals, 103 maintenance schedule, 103 mechanical stop, axis-4 replacing, 489 mechanical stop, axis-3 replacing, 486 mechanical stop, axis-2 replacing, 292 mechanical stop, axis-1 replacing, 290 mechanical stops inspecting, 111 motor, axis-6 replacing, 562 motor, axis-5 replacing, 545 motor, axis-4 replacing, 534 motor, axis-3 replacing, 523 motor, axis-2 replacing, 507 motor, axis-1 replacing, 491 mounting, equipment, 75 MoveAbsJ instruction, 738 N national regulations, 26 negative directions, axes, 718 neodymium disposal, 748 noise, 742 O oil, 29 amount in gearboxes, 129 disposal, 748 type of oil, 129 oil change axis 1, 130 axis 2, 135 oil leaks, 741 operating conditions, 39 original spare parts, 15 overfilled gearbox, 741 P pedestal installed on pedestal, 26 personnel requirements, 16 plastic disposal, 748 positive directions, axes, 718 PPE, 16 product standards, 752 protection classes, 40 protection type, 40 protective equipment, 16 protective wear, 16 R recycling, 748 regional regulations, 26 release brakes, 32 replacements, report, 141 replacing base, 208 battery pack, 122 brake release unit, 202 cable harness, 148 extender unit, 359 gearbox axis-4, 676 axis-3, 638 axis-2, 585 axis-1, 578 housing, 359 lower arm, 294 mechanical stop axis-4, 489 axis-3, 486 axis-2, 292 axis-1, 290 motor axis-6, 562 axis-5, 545 axis-4, 534 axis-3, 523 axis-2, 507 axis-1, 491 SMB unit, 193 swing, 237 766 Product manual - IRB 1300 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. Index tilt unit, 412 tubular, 412 xx, 53 report replacements, 141 requirements on foundation, 39 responsibility and validity, 15 revolution counters storing on FlexPendant, 719 updating, 719 risk of burns, 29 robot dimensions, 75 equipment, fitting, 75 labels, 19 lifting, 58 protection class, 40 protection types, 40 symbols, 19 technical data, 37 working range, 44 robot cabling inspecting, 110 rubber disposal, 748 suspended mounting, 71 swing replacing, 237 symbols safety, 17 synchronization position, 719 sync marks, 717 system integrator requirements, 26 system parameter Gravity Alpha, 72 Gravity Beta, 71 T S safety brake testing, 33 ESD, 50 fire extinguishing, 27 release robot axes, 32 signals, 17 signals in manual, 17 symbols, 17 symbols on robot, 19 test run, 99 safety devices, 27 safety signals in manual, 17 safety standards, 752 scales on robot, 717 schedule of maintenance, 103 screw joints, 755 securing, robot, 67 securing the robot to foundation, attachment screws, 67 signals safety, 17 SMB unit replacing, 193 speed adjusting, 97 standards, 752 ANSI, 752 CAN, 752 start of robot in cold environments, 97 steel disposal, 748 storage conditions, 39 technical data robot, 37 temperatures operation, 39 storage, 39 testing brakes, 33 tilt unit replacing, 412 timing belts inspecting, 115 torques on foundation, 37 Transportation bracket, 58 troubleshooting safety, 34 tubular replacing, 412 turning radius, 48 U upcycling, 748 updating revolution counters, 719 users requirements, 16 V validity and responsibility, 15 velocity adjusting, 97 verifying calibration, 737 W wall mounting, 71 weight, 37 robot, 62, 68 working range, 48 robot, 44 X xx replacing, 53 Z zero position checking, 738 Product manual - IRB 1300 767 3HAC070390-001 Revision: G © Copyright 2020-2022 ABB. All rights reserved. ABB AB Robotics & Discrete Automation S-721 68 VÄSTERÅS, Sweden Telephone +46 (0) 21 344 400 ABB AS Robotics & Discrete Automation Nordlysvegen 7, N-4340 BRYNE, Norway Box 265, N-4349 BRYNE, Norway Telephone: +47 22 87 2000 ABB Engineering (Shanghai) Ltd. Robotics & Discrete Automation No. 4528 Kangxin Highway PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 USA Telephone: +1 248 391 9000 3HAC070390-001, Rev G, en abb.com/robotics © Copyright 2020-2022 ABB. All rights reserved. Specifications subject to change without notice.
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Key Features
- Compact design
- High payload capacity
- Wide range of motion
- Standard, IP67, Foundry Plus, and Clean Room versions
- OmniCore controller
- Maintenance schedule and expected component life
- Calibration procedures
- Troubleshooting guide
Frequently Answers and Questions
What are the different protection types available for the IRB 1300?
The IRB 1300 is available in Standard, IP67, Foundry Plus, and Clean Room protection types, allowing you to choose the best configuration for your environment.
What is the expected component life for the IRB 1300?
The manual provides a maintenance schedule and expected component life for various parts, ensuring optimal performance and longevity.
How do I calibrate the IRB 1300?
The manual outlines detailed calibration procedures, including synchronization marks, revolution counters, and Axis Calibration methods.