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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 1100

35

3HAC064992-001 Revision: L

© Copyright 2019-2022 ABB. All rights reserved.

1 Safety

1.6.3 Brake testing

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Summary of Contents for IRB 1100

Page 1: ...ROBOTICS Product manual IRB 1100 ...

Page 2: ...Trace back information Workspace 22C version a10 Checked in 2022 09 29 Skribenta version 5 5 019 ...

Page 3: ...Product manual IRB 1100 4 0 475 IRB 1100 4 0 58 OmniCore Document ID 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty 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 f...

Page 5: ...stallation procedure 53 3 2 2 Risk of tipping stability 55 3 2 3 Extra O rings 56 3 2 4 Transportation bracket 3HAC068893 001 58 3 3 On site installation 58 3 3 1 Lifting the robot 58 3 3 1 1 Lifting the robot by one person 61 3 3 1 2 Lifting and rotating a suspended mounted robot 62 3 3 2 Orienting and securing the robot 66 3 3 3 Manually releasing the brakes 68 3 3 4 Setting the system parameter...

Page 6: ...the swing 342 5 5 Lower arm 342 5 5 1 Replacing the lower arm 386 5 6 Housing extender unit and wrist 386 5 6 1 Replacing the housing 440 5 6 2 Replacing the extender unit and wrist 489 5 7 Motors 489 5 7 1 Replacing the axis 1 motor 508 5 7 2 Replacing the axis 2 motor 522 5 7 3 Replacing the axis 3 motor 536 5 7 4 Replacing the axis 4 motor 549 5 7 5 Replacing the axis 5 motor 562 5 7 6 Replacin...

Page 7: ...stains on motors and gearboxes 742 7 3 Mechanical noise or dissonance 743 7 4 Manipulator collapses on power down 744 7 5 Motor temperature too high 745 8 Decommissioning 745 8 1 Introduction to decommissioning 746 8 2 Environmental information 748 8 3 Scrapping of robot 749 9 Reference information 749 9 1 Introduction 750 9 2 Applicable standards 752 9 3 Unit conversion 753 9 4 Screw joints 756 9...

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Page 9: ...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 inst...

Page 10: ... button Updated the figures of screws that are used to secure the swing to lower arm the lower arm to housing the housing to extender unit and the housing to wrist Added information of resonance sounds in troubleshooting for mechanical noise or dissonance Clarified text about position of robot and added table with depend encies between axes during Axis Calibration Clarified and added information i...

Page 11: ...ted controller OmniCore E10 is added Added spare part parallel pin on extender unit and updated related refitting procedure of extender unit Updated attachment screw information 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 H Published ...

Page 12: ...re done in this revision Updated spare part numbers for axes 1 6 motors Added expected life of gearboxes Updated information label figure L 12 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved Overview of this manual Continued ...

Page 13: ...on Troubleshooting 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 sy...

Page 14: ...dling 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 14 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved Product documentation Continued ...

Page 15: ... include specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 17 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...

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Page 17: ...ration 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 supplie...

Page 18: ...uence 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 18 Product manual IRB 1100 3HAC064992 001 Revisio...

Page 19: ...d will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous situation which if not...

Page 20: ...d to indicate where to find additional information or how to do an operation in an easier way TIP 20 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 21: ...ription Symbol Warning xx0900000812 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 xx090000...

Page 22: ...0815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 22 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 1 Safety 1 2 2 Safety...

Page 23: ... over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 1100 23 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 24: ...1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 24 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 25: ...01242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 1100 25 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 26: ...t this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 26 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Cont...

Page 27: ...ps 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 Product manual IRB 1100 27 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 28: ...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 wi...

Page 29: ...ot 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 cau...

Page 30: ...t 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 30 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 1 Safety 1 5 Safety during operati...

Page 31: ...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 Elimination Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn When working with lubricants there is a risk of an allergic reac tion Allergic reaction Ge...

Page 32: ...usly been drained from the gearbox Specified amount de pends on drained volume 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 re...

Page 33: ...us injuries on users and may damage equipment Related information See also the safety information related to installation and operation Product manual IRB 1100 33 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 1 Safety 1 6 1 Safety during maintenance and repair Continued ...

Page 34: ...ire 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 34...

Page 35: ... 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 Br...

Page 36: ...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 informati...

Page 37: ...nt 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 1100 37 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 1 Safety 1 8 Safety during decomm...

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Page 39: ... specifically for manufacturing industries that use flexible robot based automation e g 3C industry The robot has an open structure that is especially adapted for flexible use and can communicate extensively with external systems Product manual IRB 1100 39 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 2 Manipulator description 2 1 About IRB 1100 ...

Page 40: ...ions of the robots stress forces The directions are valid for all floor mounted table mounted wall mounted and suspended robots xy xy z z T F F T xx1100000521 Force in any direction in the XY plane Fxy Force in the Z plane Fz Bending torque in any direction in the XY plane Txy Bending torque in the Z plane Tz Continues on next page 40 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 201...

Page 41: ...in operation Force 710N 420 N Force xy 210 510 N 210 380 N Force z 330 Nm 180 Nm Torque xy 140 Nm 90 Nm Torque z Wall mounted Max load emergency stop Endurance load in operation Force 210 660 N 210 370 N Force xy 540 Nm 370 N Force z 370Nm 200 Nm Torque xy 140 Nm 90 Nm Torque z Suspended Max load emergency stop Endurance load in operation Force 710 N 420 N Force xy 210 510 N 210 380 N Force z 330 ...

Page 42: ...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 Disturba...

Page 43: ...s of the robot with the corresponding protection class Protection class i Protection type IP40 Manipulator protection type Standard IP67 option 3350 670 ISO 4 Manipulator protection type Clean Room 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...

Page 44: ...1 17 135 135 158 C B 173 64 78 158 57 57 xx1800002606 Description Pos Turning radius R85 A Turning radius R109 B Turning radius R61 C Continues on next page 44 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 2 Manipulator description 2 3 Dimensions ...

Page 45: ...7 135 135 158 C B 173 64 78 158 57 57 xx1800002607 Description Pos Turning radius R85 A Turning radius R109 B Turning radius R61 C Product manual IRB 1100 45 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 2 Manipulator description 2 3 Dimensions Continued ...

Page 46: ...st center and angle of axes 2 and 3 Angle degrees Positions at wrist center mm Position in the figure axis 3 axis 2 Z X 0 0 562 314 pos0 87 7 0 802 0 pos1 55 9 7 327 53 8 pos2 87 7 90 327 475 pos3 87 7 113 141 3 437 4 pos4 205 26 4 327 248 2 pos5 55 115 453 4 87 6 pos6 87 7 90 327 475 pos7 87 7 115 126 2 430 7 pos8 205 113 488 6 188 4 pos9 Continues on next page 46 Product manual IRB 1100 3HAC0649...

Page 47: ...enter and angle of axes 2 and 3 Angle degrees Positions at wrist center mm Position in the figure axis 3 axis 2 Z X 0 0 617 364 pos0 88 0 907 2 0 pos1 55 12 5 327 184 6 pos2 88 90 327 580 pos3 88 113 100 3 534 pos4 205 28 3 327 304 pos5 55 115 473 5 112 4 pos6 88 90 327 580 pos7 88 115 81 8 525 8 pos8 205 113 517 1 237 3 pos9 Continues on next page Product manual IRB 1100 47 3HAC064992 001 Revisio...

Page 48: ...ayload and the positions of other axes Simulation in RobotStudio is re commended 230 Axis 1 115 113 Axis 2 205 55 Axis 3 230 Axis 4 125 120 Axis 5 Default value 400 Axis 6 Maximum revolution value 242 The default working range for axis 6 can be extended by changing parameter values in the soft ware 48 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 2 M...

Page 49: ...roy 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 gro...

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Page 51: ...n 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 page17 before performing any installation work Note Always connect the IRB 1100 and the robot to protective earth and residual current device RCD before connecting to power and ...

Page 52: ...fting accessory used if required is suitable to handle the weight of the robot as specified in Weight robot on page 40 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 42 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 42 7 Before taking the...

Page 53: ... 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 1100 4 0 475 41 4 16 5 xx1900000106 Continues on next page Product manual IRB 1100 53 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Ins...

Page 54: ...t be removed before conducting any service work How to use the transportation bracket is described further in Transportation bracket 3HAC068893 001 on page 56 WARNING The robot is likely to be mechanically unstable if not secured to the foundation 54 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 2 2 Risk of tipping ...

Page 55: ...67 and protection type Clean Room 3HAB3772 19 O ring Used to seal between the main power cable and connector Robots with manipulator cables routed from the rear of the base xx1900002163 Robots with manipulator cables routed from below 3309 1 xx1900002164 Further information For installation information see On site installation on page 58 and Electrical connection on page 84 Product manual IRB 1100...

Page 56: ... must be refitted before shipping and transportation IRB 1100 4 0 58 IRB 1100 4 0 475 xx1800002442 xx1800002441 Removing the transportation bracket Note Action CAUTION For Clean Room robots it is important not to rub against the paint of the robot while performing any service work on the robot 1 Continues on next page 56 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All...

Page 57: ...igure remove the screws and nuts 2 xx1900000102 Remove the screws and washers 3 xx1900000103 xx1900000104 Remove the bracket 4 Product manual IRB 1100 57 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 2 4 Transportation bracket 3HAC068893 001 Continued ...

Page 58: ...ne person General This section describes how to lift the robot and move it by one person Continues on next page 58 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 3 1 1 Lifting the robot by one person ...

Page 59: ...r arm and body xx1800002445 By side When the robot is inverted grasp the robot with one hand supporting at the housing and the other hand holding the base xx1800002446 Invented Lifting and transporting the robot Action CAUTION The IRB 1100 weighs 21 1 kg and can be lifted by one person 1 Grasp the robot as instructed in Grasping location on page 59 2 Lift the robot 3 Continues on next page Product...

Page 60: ...and transporting It could damage the robot 4 Secure the robot on a workbench according to section Orienting and securing the robot on page 62 5 60 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 3 1 1 Lifting the robot by one person Continued ...

Page 61: ...ition Contact ABB for more information How to lift and turn the robot into position for wall position Contact ABB for more information Product manual IRB 1100 61 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 3 1 2 Lifting and rotating a suspended mounted robot ...

Page 62: ...8 Quality 24 x 13 x 2 5 steel hardness class 200HV Suitable washer 2 pcs D6x20 ISO 2338 6m6x20 A1 Guide pins 50 Nm 5 Nm Tightening torque Minimum 12 5 mm for ground with material yield strength 150 MPa Length of thread engagement 0 1 500 mm Level surface requirements Installation of extra O rings For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room optio...

Page 63: ...installation site for the robot con forms to the specifications in section Technical data on page 40 1 The hole configuration of the base is shown in the figure in Hole con figuration base on page 65 Prepare the installation site with attachment holes The foundation surface must be clean and un painted 2 CAUTION The weight of the IRB 1100 robot is 21 1 kg All lifting accessories used must be sized...

Page 64: ...hard ness class 200HV Tightening torque 50 Nm 5 Nm Tighten the bolts in a crosswise pattern to ensure that the base is not distorted 9 Robots with manipulator cables routed from the rear of the base xx1900002163 For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 3351 4 Fit the O ring 3HAB3772 19 to the main power connector on the robot base 10 R...

Page 65: ...1 5 11 5 5 5 6 H7 0 012 0 4x R16 135 135 11 11 10 4 R16 11 5 5 5 6 A A 10 A A 4x M12 11 11 10 4 135 135 6 H7 0 012 0 5 5 11 5 11 5 5 5 6 H7 0 012 0 4x R16 xx1800002448 Product manual IRB 1100 65 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 3 2 Orienting and securing the robot Continued ...

Page 66: ...ped with a brake release unit Note Action 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 67 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpec ted ways Make sure no personnel is near or beneath the ro bot 2 Continues on next p...

Page 67: ...to enable the brake release buttons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously and instantly 1 xx1800002443 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 2 Use the brake releasing button as described in...

Page 68: ... 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...

Page 69: ...n 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 Gravity Beta Mounting a...

Page 70: ...e 45 Tilted Pos 2 Mounting angle 90 Wall Pos 3 Mounting angle 180 Suspended Pos 4 Continues on next page 70 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 3 4 Setting the system parameters for an inverted or a tilted robot Continued ...

Page 71: ... 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 Continues on next page Prod...

Page 72: ... The system parameters are configured in RobotStudio or on the FlexPendant 72 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 3 4 Setting the system parameters for an inverted or a tilted robot Continued ...

Page 73: ...ps 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 Product manual...

Page 74: ...25 10 250 64 314 562 A 182 101 17 135 135 158 C B 173 64 78 158 57 57 xx1800002606 Description Pos Turning radius R85 A Turning radius R109 B Turning radius R61 C Continues on next page 74 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 3 6 Fitting equipment on the robot robot dimensions ...

Page 75: ...rning radius R61 C Attachment holes and dimensions Extra loads can be mounted on robot Definitions of dimensions and masses are shown in the following figures The robot is supplied with holes for fitting extra equipment Continues on next page Product manual IRB 1100 75 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 3 6 Fitting equipment on ...

Page 76: ...D 16 4x M3 x6 40 4x M5x10 4x M4x6 40 B C D 169 A 145 B xx1800002449 4 0 58 4 0 475 Pos 303 248 A 250 200 B Continues on next page 76 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 3 6 Fitting equipment on the robot robot dimensions Continued ...

Page 77: ...8 G 426 E F xx1800002450 Continues on next page Product manual IRB 1100 77 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 3 6 Fitting equipment on the robot robot dimensions Continued ...

Page 78: ... the tool at the corresponding position For details about the synchronization mark see Synchronization marks and synchronization position for axes on page 715 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 78 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2...

Page 79: ...to the I O connector on the controller Note The I O connectors provides 8 digital output signals for use Configure the lamp by adding a System Output type signal with status set to Motors On State 4 The lamp is now ready for use and is lit in MOTORS ON mode 5 Installation of signal lamp from MON_LAMP signal Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air p...

Page 80: ...s now ready for use and is lit in MOTORS ON mode 4 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 80 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installa...

Page 81: ...cal 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...

Page 82: ...f the IRB 1100 via myABB Business Portal www abb com myABB Note Article number Spare part Replace if damaged 3HAC061947 001 Mechanical stop axis 1 Replacement of the axis 1 mechanical stop The axis 1 mechanical stop is accessible after removing the base see Replacing the base on page 230 82 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation...

Page 83: ... to IPA test result the robot IRB 1100 is suitable for use in Clean Room environment Classification of airborne molecular contamination Outgassing amount Parameter Classifica tion in ac cordance to ISO 14644 8 Norm based on 1m2and 1s g Total detec ted ng Performed test Temp C Test dura tion s Area m2 6 8 1 7E 07 2848 TVOC 23 3600 4 5E 03 3 8 1 7E 04 46524 TVOC 90 60 4 5E 03 Preparations before com...

Page 84: ...fitted on the robot by the customer low voltage signals and high voltage power supply protective ground Customer cables 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 The hose for compressed air is integrated with the manipu lator cable harness Air hoses Robot...

Page 85: ... Robot cable signals Article number Signal cable length 3HAC067446 001 Signal cable shielded 3 m 3HAC067446 002 Signal cable shielded 7 m 3HAC067446 003 Signal cable shielded 15 m Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables A B xx1600002016 Diameter A Diameter x10 B Continues on next page Product manual IRB 1100 85 3HAC06...

Page 86: ...pulator and any peripheral devices xx1800002453 Installation of extra O rings For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 3351 4 Continues on next page 86 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 6 1 Robot cabling and connection points Continued ...

Page 87: ...ire 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 Article numberi Ethernet floor cable length 3HAC067447 002 7 m 3HAC067447 003 15 m i It is recommended to always use the Ethernet floor cable pr...

Page 88: ...for compressed air is also integrated into the manipulator There are 4 inlets at the base R1 8 and 4 outlets M5 on the wrist A B C A B C C xx1900000131 Value Number Description Connection Position 30 V 1 5 A 8 wiresi Customer power signal R1 R2 C1 A 30 V 1 A or 1 Gbits s 8 wires Customer power signal or Ethernet R1 R2 C2 B Outer diameter of air hose 4 mm 4 Max 6 bar Air C i The connector has 12 pi...

Page 89: ...2 Ethernet Cat5e Male straight connector kits Ethernet 3HAC067414 001 M12 Ethernet Cat5e Male angled connector kits 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 A ...

Page 90: ...r the speed regulator on the FlexPendent Start the robot with its normal program but with reduced speed Note It is recommended to reduce the speed to a value smaller than 40 of the normal pro grammed speed 1 The warm up duration varies according to the working cycle If the working cycle is not tough enough a longer warm up duration is required After 10 minutes or more run the robot with the normal...

Page 91: ...ntation velocity which is always high in predefined velocities needs to be included in the ramping up Product manual IRB 1100 91 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 3 Installation and commissioning 3 7 Start of robot in cold environments Continued ...

Page 92: ...t the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Verify that all safety equipment is installed as designed for the application 5 Verify that no personnel are inside the safeguarded space 6 If maintenance or repair has been done verify the function of the part that was main tained 7 Verify the application in the operatin...

Page 93: ...ral 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 17 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 regulati...

Page 94: ...unning 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 t...

Page 95: ...Inspecting the robot cabling on page 103 x iv Inspecting the robot harness Lubricating the cable package on page 109 x v Lubricating the robot harness Replacing the battery pack on page 111 x vi Replacing the SMB battery pack Recommended to robots without the SafeMove option See Operating manual OmniCore x viii Running the Brake Check routinevii Recommended to robots with the SafeMove option See A...

Page 96: ...is approaching v Replace when damage or cracks is detected or life limit is approaching vi The battery is to be replaced at given maintenance interval or at battery low alert vii Not needed separately if already included in the application viii Recommended test interval is within the range 8 48 hours 96 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 4...

Page 97: ... normal usage in regard to movement most material handling applications and limited use of bending backwards mode of axis 3 ii Severe chemical or thermal environments or similar environments can result in shortened life expectancy iii 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...

Page 98: ...ing 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 m...

Page 99: ...rd forces on or rub against the robot surfaces to remove dirt or debris otherwise protective paint layers may be damaged 2 Wet a clean cloth with the cleaning detergent and then wipe the robot painting surfaces Make sure no cleaning agents are sprayed onto robot surfaces or into the robot structure Wipe from the surface center to edge and always in the same direction 3 Wait a few minutes for deter...

Page 100: ...eely 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 100 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 4 Maintenance 4 3 1 Cleaning the IRB 1100 Continued ...

Page 101: ...oom ABB logo Rating label Calibration label A A A B C D E F G xx1800003316 ABB logo A Instruction label B Brake release UL label C Read manual label also specifying warning labels D Clean Room label E Rating label CE label and AbsAcc label F Calibration label G Required tools and equipment Visual inspection no tools are required Continues on next page Product manual IRB 1100 101 3HAC064992 001 Rev...

Page 102: ...upply to the robot before entering the safeguarded space 1 Inspect the labels located as shown in the figures 2 Replace any missing or damaged labels 3 102 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 4 Maintenance 4 4 1 Inspecting the information labels Continued ...

Page 103: ...red 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 Note Action 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 1 Visually inspect the control cabling between the robot ...

Page 104: ... surface on the robot before replacing parts on page 123 Location of timing belts Note It is recommended to inspect the axis 1 and axis 4 timing belts when replacing the motors Continues on next page 104 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 4 Maintenance 4 4 3 Inspecting timing belts ...

Page 105: ...n in the figures Location Axis xx1800002457 1 xx1800002458 2 3 Continues on next page Product manual IRB 1100 105 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 4 Maintenance 4 4 3 Inspecting timing belts Continued ...

Page 106: ... Axis xx1800002459 xx1800002460 4 5 Continues on next page 106 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 4 Maintenance 4 4 3 Inspecting timing belts Continued ...

Page 107: ...lkit on page 757 Standard toolkit Other tools and procedures may be required if the spare part needs to be replaced These are specified in the replacement procedure Continues on next page Product manual IRB 1100 107 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 4 Maintenance 4 4 3 Inspecting timing belts Continued ...

Page 108: ...or 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 ii The value range is only for reference Inspecting timing belts Use this procedure to inspect timing belts Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot befor...

Page 109: ...ndard toolkit Other tools and procedures may be required if the spare part needs to be replaced These are specified in the replacement procedure Required consumables Note Article number Consumable FM 222 3HAC029132 001 Grease Lubricating the cable package Use this procedure to lubricate the cable package Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pre...

Page 110: ...cable package on page 178 If any damage or wear is detected the part must be replaced 4 Apply grease to the cable package cover all moving area of the package 5 Apply grease to the covers that have con tacting area with the cable package 6 110 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 4 Maintenance 4 5 1 Lubricating the cable package Continued ...

Page 111: ... be out of date See the latest spare parts of the IRB 1100 via myABB Business Portal www abb com myABB Note Article number Spare part Battery includes protection cir cuits Only replace with the spe cified spare part or an ABB ap proved equivalent 3HAC044075 001 Battery pack Continues on next page Product manual IRB 1100 111 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 4 Ma...

Page 112: ...tion tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease Removing the battery pack Use these procedures to remove the battery pack Preparations before removing the battery pack Note Action Decide which calibration routine to use and take actions accordingly prior to beginning t...

Page 113: ...aint or surface on the robot before replacing parts on page 123 4 Disconnecting the SMB connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 49 2 Continues on next...

Page 114: ...until the connectors are removed 4 xx1800002468 Disconnect the connectors SMB P7 SMB J1 SMB J2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 5 Remove the SMB cover completely from the base 6 Removing the battery pack Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are tu...

Page 115: ... Use these procedures to refit the battery pack Refitting the battery pack Note Action 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 49 1 For robots with protection type Clean Room 2 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free ...

Page 116: ...handling the unit read the safety information in section The unit is sensitive to ESD on page 49 1 For robots with protection type Clean Room 2 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 116 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 4 Maintenance 4 6 1 Replacing ...

Page 117: ... to the base 5 Tightening torque 1 2 Nm xx1800002467 Concluding procedure Note Action For robots with protection type Clean Room 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Ca...

Page 118: ...ure all safety requirements are met when performing the first test run 3 118 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 4 Maintenance 4 6 1 Replacing the battery pack Continued ...

Page 119: ...is 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 17 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 1100 is connected to power always make sure that the IRB...

Page 120: ... 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 Note Action Check the sealing to ensure that The sealing is of the correct type There is no damage on the main lip 1 Inspect the shaft surface before mounting If scratches o...

Page 121: ...and the main lip with grease If the sealing is without dust lip just lubricate the main lip with a thin layer of grease 3 A xx2000000072 A Gap Mount the sealing correctly with a mounting tool Never hammer directly on the sealing as this may result in leakage 4 Make sure that no grease is left on the robot surface 5 Continues on next page Product manual IRB 1100 121 3HAC064992 001 Revision L Copyri...

Page 122: ...tening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Check the o ring grooves 3 The grooves must be geometrically correct and should be free of pores and contami...

Page 123: ... made of wood Tooling pin Ethanol Cleaning agent Knife Lint free cloth White 3HAC036639 001 Touch up paint Clean Room Hy gienic Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Refitting Descript...

Page 124: ...time 10 minutes 3HAC036639 001 Use Touch up paint Clean Room Hygienic white to paint any damaged surfaces Note Always read the instruction in the product data sheet in the paint repair kit for Clean Room Hygienic 6 Note After all repair work wipe the robot free from particles with spirit on a lint free cloth 124 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights r...

Page 125: ...ng and then into the wrist The main cable package includes the cabling for all the six motors Optional air hoses CP CS cabling and Ethernet cabling can also be included 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 Continues on next page Product manual IRB 1100 125 3HAC...

Page 126: ...IRB 1100 4 0 475 3HAC060419 002 Upper cable harness CP CS and air hose without Ethernet Used with IRB 1100 4 0 475 3HAC060419 003 Upper cable harness CP CS and air hose with Ethernet Used with IRB 1100 4 0 58 3HAC060416 001 Extension upper cable harness basic Used with IRB 1100 4 0 58 3HAC060416 002 Extension upper cable harness CP CS and air hose without Ether net Used with IRB 1100 4 0 58 3HAC06...

Page 127: ...ction type Clean Room 3HAC075500 001 Swing support cover Clean Room 3HAC069061 001 Wrist cover Used with protection type Clean Room 3HAC075507 001 Wrist cover Clean Room 3HAC069054 001 Housing cover Used with protection type Clean Room 3HAC075501 001 Housing cover Clean Room 3HAC069057 001 Lower arm cover Used with protection type Clean Room 3HAC075503 001 Lower arm cover Clean Room 3HAC069059 001...

Page 128: ... and protection type Clean Room Replace if damaged 3HAC067995 001 Rubber sealing washer on ex tender unit Used with protection classes IP40 and IP67 Replace if damaged 3HAC064146 001 Plug screw Used with protection type Clean Room Replace if damaged 3HAC070309 001 Plug screw Clean Room Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page...

Page 129: ...bration 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 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or...

Page 130: ...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 123 4 Removing the axis 2 motor Note Action DANGER Mak...

Page 131: ...all down Make sure axes are well supported before remov ing motors 3 xx1800002488 Remove the swing support cover 4 xx1800002489 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 re move from the plate 5 Continues on next page Product manual IRB 1100 131 3HAC064992 001 Revisi...

Page 132: ...s a reference when reconnecting 6 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 7 xx1800002492 Remove the swing cover 8 Continues on next page 132 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 133: ... lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 12 Continues on next page Pr...

Page 134: ...essure are turned off 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 123 2 Continues on next page 134 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the...

Page 135: ...swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100...

Page 136: ...obots 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 123 2 xx1800002500 Disconnect the air hoses from the Y shaped con nectors 3 Continues on next page 136 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights rese...

Page 137: ...b Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 137...

Page 138: ...ing steps 3 xx1800002945 Disconnect the air hoses 4 xx1800002947 For robots with CP CS cabling Disconnect the connector J5 C1 5 J5 C2 connector assembly tool xx1800002948 For robots with Ethernet cabling Disconnect the connector J5 C2 using the tool 6 Continues on next page 138 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing th...

Page 139: ...wrist covers from both sides 3 Disconnecting the axis 5 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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...

Page 140: ...ydraulic pressure and air pressure are turned off 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 123 2 Continues on next page 140 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved ...

Page 141: ...when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 4 Continues on next page Product manual IRB 1100 141 3HAC0649...

Page 142: ... power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page 142 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights r...

Page 143: ...ess the cable package locking screw on the axis 4 gearbox and then loosen the locking screw 4 xx1800003001 Separating the upper cable harness from the axis 2 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 143 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights r...

Page 144: ...e that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 xx1800003003 Remove the lower arm support cover 3 Continues on next page 144 Pr...

Page 145: ...isconnect the connectors FB3 MP3 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 5 xx1800003006 Remove the cable bracket 6 Removing the axis 3 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 145 3HAC0649...

Page 146: ...t or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 Continues on next page 146 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 147: ...lly lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 7 Continues on next page Product manual IRB 1100 147 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable p...

Page 148: ...ressure are turned off 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 123 2 Continues on next page 148 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing th...

Page 149: ...ure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 149 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1...

Page 150: ...ed off 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 123 2 Continues on next page 150 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable pa...

Page 151: ...Refitting the upper cable harness through the axis 4 gearbox Note Action For robots with protection type Clean Room 1 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 1100 151 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continu...

Page 152: ...ectors with the masking tape CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 2 xx1800003601 Securing the upper cable package to the axis 4 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 152 Product manual IRB 1100 3...

Page 153: ...able protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 2 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page Product manual IRB 1100 153 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 154: ...Valid for IRB 1100 4 0 475 xx1800003031 Note If there is locking liquid residues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for IRB 1100 4 0 58 xx1800003001 Continues on next page 154 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Con...

Page 155: ...opened and wipe the parts free from particles with spirit on a lint free xx1800003016 Guide the upper cable package to go though from the housing though the lower arm down to the swing When inserting the cable package leave the axis 4 motor connectors in the housing and the axis 3 motor connectors in the lower arm Tip Wrap the connectors with the masking tape Tip It is possible to remove the lower...

Page 156: ... 6 Nm xx1800003014 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 3 Reconnecting the axis 4 motor connectors Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Cont...

Page 157: ...ing the axis 3 motor Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Continues on next page Product manual IRB 1100 157 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserve...

Page 158: ...otor con nector xx1800003021 Orient the motor correctly and fit it into the lower arm 4 Screw M4x12 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 5 Washer 3HAC063985 001 3 pcs xx1800003009 Continues on next page 158 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable pac...

Page 159: ...re screw to the hole 7 Initial referenced force for used belt 21 7 23 94 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 8 Initial referenced force for new belt 31 34 2 N Continues on next page Product manual IRB 1100 159 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacin...

Page 160: ...asure the timing belt tension 10 New belt 113 143 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 11 Continues on next page 160 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 161: ... into the connector plate and reconnect the connectors FB3 MP3 Tip See the number markings on the connectors for help to find the corresponding connector 2 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 3 Continues on next page Product manual IRB 1100 161 3HAC064992 001 Revi...

Page 162: ... xx1800003004 Securing the upper cable package to the axis 2 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 162 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package...

Page 163: ...ean and without damages the motor is clean and undamaged 2 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003023 Orient the motor correctly and fit it into the lower arm Tip Leave the connectors FB5 and FB6 accessible from the process hub and the connectors MP5 and MP6 accessible from wrist side 3 Continues on next page Product ma...

Page 164: ...justment screw to the motor Note Do not insert the entire screw to the hole 6 Initial referenced force for used belt 8 96 9 8 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 7 Initial referenced force for new belt 12 8 14 xx1900000026 Continues on next page 164 Product manual IRB 1100 3HAC064992 001 Revision L Cop...

Page 165: ... the motor screws and readjust 10 xx1900000007 Remove the adjustment screw from the motor 11 Reconnecting the axis 5 motor connectors Note Action For robots with protection type Clean Room 1 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 1100 165 3HAC064992 001 Revision L Copyright 2019 2022 ABB All...

Page 166: ... Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800002994 Reconnect the connectors FB6 MP6 Tip See the number markings on the connectors for help to find the corresponding connector 2 Route and secure the cabling with cable straps CAUTION Correct cable routing is highly important If the cables are routed and secured incorrec...

Page 167: ...or robots with protection type Clean Room option 3351 4 Check the gasket Replace if damaged 2 xx1800002945 Reconnect the air hoses in a cross pattern Tip See the number markings on the air hoses for help to find the corresponding air hoses The air hoses with the same number connect to the same Y shaped connector 3 Continues on next page Product manual IRB 1100 167 3HAC064992 001 Revision L Copyrig...

Page 168: ...ool 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 Screw M3x8 12 9 Lafre 2C2B FC6 9 4 pcs Refit the cover 7 Tightening torque 1 2 Nm xx1800002944 Continues on next page 168 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Re...

Page 169: ...oses The air hoses with the same number connect to the same Y shaped connector 2 xx1800002501 Reconnect the connectors J2 C1 J2 C2 Tip See the number markings on the connectors for help to find the corresponding connector 3 Securing the cable package to the swing Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles w...

Page 170: ...ee from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003603 Check the cooling pad Replace if damaged as shown in the following step 3 Continues on next page 170 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserv...

Page 171: ...on nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 5 Screw M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC063985 001 3 pcs xx1800002494 Continues on next page Product manual IRB 1100 171 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights ...

Page 172: ... to the hole 8 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 9 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page 172 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1...

Page 173: ... the timing belt tension 11 New belt 180 229 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 12 Continues on next page Product manual IRB 1100 173 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 174: ...he division point Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003029 Insert the female header of the connectors to the connector plate 2 Continues on next page 174 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Rep...

Page 175: ...incorrectly the cables can be damaged 4 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 5 Tightening torque 0 8 Nm xx1800002489 Refitting the covers Note Action For robots with protection type Clean Room 1 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 1100 175 3HAC064992 001 Revisi...

Page 176: ...Swing cover Swing support cover 5 Tightening torque 1 2 Nm xx1800003606 Concluding procedure Note Action For robots with protection type Clean Room 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is det...

Page 177: ...re all safety requirements are met when performing the first test run 3 Product manual IRB 1100 177 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 1 Replacing the upper cable package Continued ...

Page 178: ... 3HAC075514 001 Lower cable harness basic Clean Room Used with protection classes IP40 and IP67 3HAC075522 001 Lower cable harness CP CS and air hose without Ethernet Used with protection type Clean Room 3HAC075515 001 Lower cable harness Clean Room CP CS and air hose without Ether net Used with protection classes IP40 and IP67 3HAC075523 001 Lower cable harness CP CS and air hose with Ethernet Us...

Page 179: ...ed with protection type Clean Room 3HAC075506 001 SMB cover Clean Room Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAC065345 001 Gasket for base bottom Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAC065350 001 Gasket for base rear Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAC06195...

Page 180: ...ber Consumable Cable straps FM 222 3HAC029132 001 Grease Loctite 243 3HAB7116 1 Locking liquid 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 Note Action Note Calibrating axis 6 always requires tools to be remove...

Page 181: ... reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the lower cable package Use these procedures to remove the lower cable package Preparations before removing the lower cable package Note Action Decide which calibration routine to use and take actions accordingly prior to begin...

Page 182: ...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 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 xx1800002488 Remove the swing support...

Page 183: ...e connector J2 FB2 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 6 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 7 xx1800002492 Remove the swing cover 8 Continues on next page Product manual IRB 1100 183 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repa...

Page 184: ... lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 12 Continues on next page 18...

Page 185: ...ays 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 123 2 xx1800003032 Access the cable package locking screw on the axis 1 gearbox from the swing and then loosen the locking screw 3 Remove the locking screw 4 Continues on next page Product manual IRB 1100 185 3HAC064992 001 Revision ...

Page 186: ...Disconnect the connectors J2 FB3 4 5 6 J2 MP3 4 5 6 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 3 xx1800002498 Snap loose and remove the female head of the connectors from the connector plate 4 Separating the cable package from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure ...

Page 187: ...ke sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 xx1800002500 Disconnect the air hoses from the Y shaped con nectors 3 Con...

Page 188: ...c pressure and air pressure are turned off 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 49 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 be...

Page 189: ...eference when reconnecting 5 Remove the SMB cover completely from the base 6 Putting the robot on its side Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 sur...

Page 190: ...that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page 190 Product manual IRB 1100 3HAC064992 001 Revision L Copy...

Page 191: ...ere are cabling attached to the cover The cover cannot be removed completely until the connectors are removed 3 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page Product manual IRB 1100 191 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 192: ...e that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page 192 Product manual IRB 1100 3HAC064992 001 Revision L Co...

Page 193: ...bling with bottom interface option 3309 1 Remove the base rear cover 4 xx1800003036 Disconnect the earth cable 5 Remove the connector plate 6 Continues on next page Product manual IRB 1100 193 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 194: ...ote Action xx1800003037 Continues on next page 194 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 195: ... button assembly tool included in the special toolkit 3HAC071022 001 xx1800003040 Remove the brake release button from the base using the tool 9 Disconnecting axis 1 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 195 3HAC064992 001 Revision L Copyright 2019 2022...

Page 196: ...hen reconnecting 3 Separating the cable package from the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 p...

Page 197: ...or 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 123 2 xx1800003043 Remove the pulley cover 3 Continues on next page Product manual IRB 1100 197 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 2 Replaci...

Page 198: ... parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 xx1800003044 Pull out the lower cable package from the axis 1 gearbox 3 xx1800003045 Pull out the lower cable package from the base 4 xx1800003046 Remove the pulley cover from the lower cable package 5 Continues on next page 198 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 AB...

Page 199: ...ector yet Do not tighten the button yet 2 Refitting the lower cable package through the axis 1 gearbox Notice that the procedure differs depending on if the connector interface is located either at the rear or at the bottom of the base Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx...

Page 200: ...ed or strained Reroute if necessary 3 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Continues on next page 200 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair ...

Page 201: ...the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Securing the lower cable package to the axis 1 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on...

Page 202: ...e cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 2 xx1800003049 xx1800003050 Continues on next page 202 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 203: ...s with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Screw M3x8 12 9 Lafre 2C2B FC6 9 3 pcs Refit the puller cover 2 Tightening torque 1 2 Nm xx1800003043 Checking the SMB cover gasket Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from pa...

Page 204: ...n the joints that have been opened and wipe the parts free from particles with spirit on a lint free Tightening torque 0 3 Nm xx1800002468 Reconnect the connectors SMB P7 SMB J1 SMB J2 Tip See the number markings on the connectors for help to find the corresponding connector 3 Route and secure the cabling with cable straps CAUTION Correct cable routing is highly important If the cables are routed ...

Page 205: ...rface plate Note Action For robots with protection type Clean Room 1 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 1100 205 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 206: ...d for cabling with bottom inter face option 3309 1 Gasket for base bottom 3HAC065345 001 xx1900002188 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 3 Continues on next page 206 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 R...

Page 207: ...B FC6 9 6 pcs Refit the connector interface plate to the base 5 Tightening torque 1 2 Nm Valid for cabling with rear inter face xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page Product manual IRB 1100 207 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 208: ...uring the brake release button Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free brake release button assembly tool included in the special toolkit 3HAC071022 001 xx1800003040 Tighten the brake release button using the tool 2 Continues on next page 208 Product manual IRB 1100 3HAC064992 ...

Page 209: ...he connectors J1M BR MP1 FB1 Tip See the number markings on the connectors for help to find the corresponding connector 2 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Reconnect the floor cable together with the con nector plate 3 Tightening torque 0 8 Nm xx1800003037 xx1800003036 Continues on next page Product manual IRB 1100 209 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Re...

Page 210: ...rotection type Clean Room option 3351 4 Check the gasket Replace if damaged Valid for cabling with bottom inter face option 3309 1 Gasket for base rear 3HAC065350 001 xx1900002189 Apply grease to the cable package cover all moving area of the package 3 Apply grease to the covers that have contacting area with the cable package 4 Route and secure the cabling with cable straps CAUTION Correct cable ...

Page 211: ...oints that have been opened and wipe the parts free from particles with spirit on a lint free CAUTION The IRB 1100 robot weighs 21 1 kg and can be lifted by one person 2 Attachment screws M12x25 robot installation directly on foundation quality 8 8 Raise the robot to standing and secure to the foundation with the attachment screws and washers 3 Washers 24 x 13 x 2 5 steel hard ness class 200HV Tig...

Page 212: ...oses The air hoses with the same number connect to the same Y shaped connector 2 xx1800002501 Reconnect the connectors J2 C1 J2 C2 Tip See the number markings on the connectors for help to find the corresponding connector 3 Securing the cable package to the swing Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles w...

Page 213: ...ee from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003603 Check the cooling pad Replace if damaged as shown in the following step 3 Continues on next page Product manual IRB 1100 213 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserv...

Page 214: ...on nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 5 Screw M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC063985 001 3 pcs xx1800002494 Continues on next page 214 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights ...

Page 215: ... to the hole 8 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 9 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page Product manual IRB 1100 215 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 2...

Page 216: ... the timing belt tension 11 New belt 180 229 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 12 Continues on next page 216 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 2 Replacing the lower cable package Continued ...

Page 217: ...he division point Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003029 Insert the female header of the connectors to the connector plate 2 Continues on next page Product manual IRB 1100 217 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 2 Rep...

Page 218: ...orrectly the cables can be damaged 4 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 5 Tightening torque 0 8 Nm xx1800002489 Refitting the swing covers Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 218 Product manual IRB 1100 3HAC064992 001 Rev...

Page 219: ...003607 Concluding procedure Note Action For robots with protection type Clean Room 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robot 2 ...

Page 220: ...ss Portal www abb com myABB Note Article number Spare part 3HAC063968 001 Serial measurement unit 3HAC069060 001 SMB cover Used with protection type Clean Room 3HAC075506 001 SMB cover Clean Room Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAC065344 001 Gasket for SMB cover Continues on next page 220 Product manual IRB 1100 3HAC064992 001 Revision L Copyright...

Page 221: ...ction Note Calibrating axis 6 always requires tools to be removed from the mounting flange also for reference calibration since the mount ing flange is used for installation of the calibration tool 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 packa...

Page 222: ...og the robot to the synchronization position 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...

Page 223: ...3 xx1800002467 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 There are cabling attached to the cover The cover cannot be removed completely until the connectors are removed 4 xx1800002468 Disconnect the connectors SMB P7 SMB J1 ...

Page 224: ...tion in section The unit is sensitive to ESD on page 49 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 123 3 Continues on next page 224 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights res...

Page 225: ...ive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 49 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 123 3 Continues on next page Product manual IRB 1100 225 3HAC0...

Page 226: ...ction The unit is sensitive to ESD on page 49 1 For robots with protection type Clean Room 2 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Screw M3x5 12 9 Lafre 2C2B FC6 9 4 pcs Refit the screws 3 Tightening torque 0 8 Nm xx1800002471 Continues on next page 226 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All r...

Page 227: ...particles with spirit on a lint free xx1800002470 Secure the battery pack using the cable strap 3 xx1800002469 Reconnect the battery cable 4 Reconnecting the SMB connectors Note Action 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 49 1 Continues on next page Product manual IRB 1100 227 3...

Page 228: ... help to find the corresponding connector 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 4 Screw M3x8 12 9 Lafre 2C2B FC6 9 6 pcs Refit the SMB cover to the base 5 Tightening torque 1 2 Nm xx1800002467 Continues on next page 228 Product manual IRB 1100 3HAC064992 001 Revis...

Page 229: ...ter all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 Product manual IRB 1100 229 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 3 3 Replacing the SMB u...

Page 230: ...le harness basic Used with protection type Clean Room 3HAC075514 001 Lower cable harness basic Clean Room Used with protection classes IP40 and IP67 3HAC075522 001 Lower cable harness CP CS and air hose without Ethernet Used with protection type Clean Room 3HAC075515 001 Lower cable harness Clean Room CP CS and air hose without Ether net Used with protection classes IP40 and IP67 3HAC075523 001 Lo...

Page 231: ...robots with bottom con nector interface Used with protection type Clean Room 3HAC075513 001 Base rear cover Clean Room Used for robots with bottom con nector interface 3HAC070313 001 Base adapter Used for robots with bottom con nector interface Used with protection type Clean Room 3HAC075793 001 Base adapter Clean Room 3HAC069051 001 Swing cover Used with protection type Clean Room 3HAC075498 001 ...

Page 232: ...page 757 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Used for measuring the tim...

Page 233: ...If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Product manual IRB 4600 If no previous refe...

Page 234: ... robot before replacing parts on page 123 4 Removing the axis 2 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 pa...

Page 235: ... cover 4 xx1800002489 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 re move from the plate 5 Continues on next page Product manual IRB 1100 235 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 236: ... have as a reference when reconnecting 6 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 7 xx1800002492 Remove the swing cover 8 Continues on next page 236 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 237: ...arefully lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 12 Continues on next...

Page 238: ...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 123 2 xx1800003032 Access the cable package locking screw on the axis 1 gearbox from the swing and then loosen the locking screw 3 Remove the locking screw 4 Continues on next page 238 Product manual IRB 1100 3HAC064992 001 R...

Page 239: ...0002497 Disconnect the connectors J2 FB3 4 5 6 J2 MP3 4 5 6 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 3 xx1800002498 Snap loose and remove the female head of the connectors from the connector plate 4 Separating the cable package from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic p...

Page 240: ...ANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 xx1800002500 Disconnect the air hoses from the Y shaped con necto...

Page 241: ...re that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 CAUTION The IRB 1100 robot weighs 21 1 kg and can be lifted by one person 3 Co...

Page 242: ...re turned off 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 49 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 ...

Page 243: ...n before disconnecting them to have as a reference when reconnecting 5 Remove the SMB cover completely from the base 6 Opening the connector interface plate Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disasse...

Page 244: ...UTION There are cabling attached to the cover The cover cannot be removed completely until the connectors are removed 3 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page 244 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 245: ...Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 245 3HAC064992 001 Revis...

Page 246: ... for cabling with bottom interface option 3309 1 Remove the base rear cover 4 xx1800003036 Disconnect the earth cable 5 Remove the connector plate 6 Continues on next page 246 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 247: ...Note Action xx1800003037 Continues on next page Product manual IRB 1100 247 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 248: ...release button assembly tool included in the special toolkit 3HAC071022 001 xx1800003040 Remove the brake release button from the base using the tool 9 Disconnecting axis 1 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 248 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 20...

Page 249: ...erence when reconnecting 3 Separating the cable package from the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 pa...

Page 250: ...AUTION 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 123 2 xx1800003043 Remove the pulley cover 3 Continues on next page 250 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1...

Page 251: ...sembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 xx1800003044 Pull out the lower cable package from the axis 1 gearbox 3 xx1800003045 Pull out the lower cable package from the base 4 xx1800003046 Remove the pulley cover from the lower cable package 5 Continues on next page Product manual IRB 1100 251 3HAC064992 001 Revision L Copyright 2019...

Page 252: ...s of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 xx1800003064 Loosen the screws and move the motor slightly to slacken the timing belt 4 Continues on next page 252 Product manual IRB 1100 3HAC064992 001 Revision L Copyr...

Page 253: ...om the casting Pay attention not to scratch the casting or damage the pad 6 xx1800003066 Remove the timing belt from its groove on the motor 7 Removing the axis 1 timing belt Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 253 3HAC064992 001 Revision L Copyright 2019 2022 ABB All...

Page 254: ...Remove the timing belt from its groove on the gearbox 4 Separating the base from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 robo...

Page 255: ...em to have as a reference when refitting xx1800003068 3 xx1800003070 Separate the base from the swing CAUTION The axis 1 mechanical stop is accessible now Put it aside for later refitting xx1800003071 4 Continues on next page Product manual IRB 1100 255 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 256: ...the axis 1 gearbox must be removed from the swing if not already removed 2 Grease 3HAC029132 001 Apply a little grease to the new sealing when re placing the radial sealing and wipe clean after the replacement 3 xx1900002154 Place the new sealing in its groove in the swing 4 Axis 1 radial sealing assembly tool included in the radial sealing as sembly tool set 3HAC074609 001 xx1900002155 Place the ...

Page 257: ...9 Check that the sealing is undamaged and properly fitted 10 Placing the axis 1 mechanical stop Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Mechanical stop axis 1 3HAC061947 001 Check the axis 1 mechanical stop Replace if damaged 2 Continues on next page Product manual IRB 1100 257...

Page 258: ...figure is fa cing the swing when putting xx1800003619 3 Refitting the base to the swing Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 258 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the ...

Page 259: ...oom 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free brake release button assembly tool included in the special toolkit 3HAC071022 001 xx1800003040 Refit the brake release button Note Do not reconnect the connector yet Do not tighten the button yet 2 Continues on next page Product manual IRB 1100 259 3HAC064992 001 Revision L Copyright 2019...

Page 260: ...t damages the motor is clean and undamaged 2 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003602 Check the cooling pad Replace if damaged 3 xx1800003085 Install the timing belt to the motor pulley and verify that the belt runs correctly in the groove of the pulley 4 Continues on next page 260 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved...

Page 261: ...y 5 Screw M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC063985 001 3 pcs xx1800003065 Adjusting the axis 1 timing belt tension Note Action For robots with protection type Clean Room 1 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 1100...

Page 262: ...00000041 Tightening torque 3 Nm Secure the motor with the screws 4 Securing the brake release button Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free brake release button assembly tool included in the special toolkit 3HAC071022 001 xx1800003040 Tighten the brake release button using the...

Page 263: ...abling with rear interface Insert the cable package in the base and up through the axis 1 gearbox through the rear Tip Wrap the connectors with the masking tape CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 3 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should b...

Page 264: ...tch on the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Securing the lower cable package to the axis 1 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Conti...

Page 265: ...arbox The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 2 xx1800003049 xx1800003050 Continues on next page Product manual IRB 1100 265 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 266: ...or robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Screw M3x8 12 9 Lafre 2C2B FC6 9 3 pcs Refit the puller cover 2 Tightening torque 1 2 Nm xx1800003043 Checking the SMB cover gasket Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free...

Page 267: ...m 2 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Tightening torque 0 3 Nm xx1800002468 Reconnect the connectors SMB P7 SMB J1 SMB J2 Tip See the number markings on the connectors for help to find the corresponding connector 3 Route and secure the cabling with cable straps CAUTION Correct cable routing is highly important If the cables are...

Page 268: ...t on a lint free Screw M2 5x6 12 9 Lafre 2C2B FC6 9 2 pcs Refit the cable bracket 2 Tightening torque 0 6 Nm xx1800003042 Reconnecting the brake release cabling and axis 1 motor connectors Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 268 Product manual IRB 110...

Page 269: ...sponding connector 2 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Reconnect the floor cable together with the con nector plate 3 Tightening torque 0 8 Nm xx1800003037 xx1800003036 Continues on next page Product manual IRB 1100 269 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 270: ...s with protection type Clean Room option 3351 4 Check the gasket Replace if damaged Valid for cabling with bottom inter face option 3309 1 Gasket for base rear 3HAC065350 001 xx1900002189 Apply grease to the cable package cover all moving area of the package 3 Apply grease to the covers that have contacting area with the cable package 4 Route and secure the cabling with cable straps CAUTION Correc...

Page 271: ...309 1 7 Tightening torque 1 2 Nm xx1800003057 Refit the rear cover Refitting the connector interface plate Note Action For robots with protection type Clean Room 1 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 1100 271 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5...

Page 272: ...ed Valid for cabling with bottom inter face option 3309 1 Gasket for base bottom 3HAC065345 001 xx1900002188 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 3 Continues on next page 272 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reser...

Page 273: ...fre 2C2B FC6 9 6 pcs Refit the connector interface plate to the base 5 Tightening torque 1 2 Nm Valid for cabling with rear inter face xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page Product manual IRB 1100 273 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 274: ...CS cabling and Ethernet cabling if equipped Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800002500 Reconnect the air hoses in a cross pattern to the Y shaped connectors Tip See the number markings on the air hoses for help to find the corresponding air hoses The air hoses with th...

Page 275: ... robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003603 Check the cooling pad Replace if damaged as shown in the following step 3 Continues on nex...

Page 276: ...motor con nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 5 Screw M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC063985 001 3 pcs xx1800002494 Continues on next page 276 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All ...

Page 277: ...e screw to the hole 8 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 9 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page Product manual IRB 1100 277 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repai...

Page 278: ... measure the timing belt tension 11 New belt 180 229 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 12 Continues on next page 278 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the base Continued ...

Page 279: ...rs at the division point Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003029 Insert the female header of the connectors to the connector plate 2 Continues on next page Product manual IRB 1100 279 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 ...

Page 280: ...red incorrectly the cables can be damaged 4 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 5 Tightening torque 0 8 Nm xx1800002489 Refitting the swing covers Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 280 Product manual IRB 1100 3HAC064992 ...

Page 281: ...m xx1800003607 Concluding procedure Note Action For robots with protection type Clean Room 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the ...

Page 282: ...om myABB Note Article number Spare part Used with protection classes IP40 and IP67 3HAC075521 001 Lower cable harness basic Used with protection type Clean Room 3HAC075514 001 Lower cable harness basic Clean Room Used with protection classes IP40 and IP67 3HAC075522 001 Lower cable harness CP CS and air hose without Ethernet Continues on next page 282 Product manual IRB 1100 3HAC064992 001 Revisio...

Page 283: ...Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAB3701 70 Axis 2 radial sealing 3HAC069062 001 Gear unit with pulley axis 1 3HAC083589 001 Motor with flange axis 1 3HAC061934 001 Timing belt axis 1 3HAC083588 001 Motor with flange axis 2 3HAC061935 001 Timing belt axis 2 Replace if damaged 3HAC061947 001 Mechanical stop axis 1 Standard configuration used for rob...

Page 284: ...ad sheet contains 6 pieces of small pad Replace if damaged with one piece each time 3HAC071020 001 Cooling pad for axis 1 and 2 mo tors 9x4 3x1 Steel 3HAC063985 001 Washer Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 757 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration...

Page 285: ...sPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot C...

Page 286: ... robot before replacing parts on page 123 4 Removing the axis 2 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 pa...

Page 287: ... cover 4 xx1800002489 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 re move from the plate 5 Continues on next page Product manual IRB 1100 287 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 288: ... have as a reference when reconnecting 6 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 7 xx1800002492 Remove the swing cover 8 Continues on next page 288 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 289: ...refully lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 12 Continues on next ...

Page 290: ...oom 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 123 2 xx1800003032 Access the cable package locking screw on the axis 1 gearbox from the swing and then loosen the locking screw 3 Remove the locking screw 4 Continues on next page 290 Product manual IRB 1100 3HAC064992 001 Re...

Page 291: ...002497 Disconnect the connectors J2 FB3 4 5 6 J2 MP3 4 5 6 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 3 xx1800002498 Snap loose and remove the female head of the connectors from the connector plate 4 Separating the cable package from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pr...

Page 292: ...NGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 xx1800002500 Disconnect the air hoses from the Y shaped con nector...

Page 293: ...e that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 CAUTION The IRB 1100 robot weighs 21 1 kg and can be lifted by one person 3 Con...

Page 294: ...e turned off 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 49 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 1...

Page 295: ... before disconnecting them to have as a reference when reconnecting 5 Remove the SMB cover completely from the base 6 Opening the connector interface plate Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassem...

Page 296: ...TION There are cabling attached to the cover The cover cannot be removed completely until the connectors are removed 3 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page 296 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 297: ...ake sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 297 3HAC064992 001 Revisi...

Page 298: ... for cabling with bottom interface option 3309 1 Remove the base rear cover 4 xx1800003036 Disconnect the earth cable 5 Remove the connector plate 6 Continues on next page 298 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 299: ...Note Action xx1800003037 Continues on next page Product manual IRB 1100 299 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 300: ...release button assembly tool included in the special toolkit 3HAC071022 001 xx1800003040 Remove the brake release button from the base using the tool 9 Disconnecting axis 1 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 300 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 20...

Page 301: ...rence when reconnecting 3 Separating the cable package from the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 par...

Page 302: ...UTION 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 123 2 xx1800003043 Remove the pulley cover 3 Continues on next page 302 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 ...

Page 303: ...embling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 xx1800003044 Pull out the lower cable package from the axis 1 gearbox 3 xx1800003045 Pull out the lower cable package from the base 4 xx1800003046 Remove the pulley cover from the lower cable package 5 Continues on next page Product manual IRB 1100 303 3HAC064992 001 Revision L Copyright 2019 ...

Page 304: ... of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 xx1800003064 Loosen the screws and move the motor slightly to slacken the timing belt 4 Continues on next page 304 Product manual IRB 1100 3HAC064992 001 Revision L Copyri...

Page 305: ...m the casting Pay attention not to scratch the casting or damage the pad 6 xx1800003066 Remove the timing belt from its groove on the motor 7 Removing the axis 1 timing belt Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 305 3HAC064992 001 Revision L Copyright 2019 2022 ABB All ...

Page 306: ...emove the timing belt from its groove on the gearbox 4 Separating the base from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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...

Page 307: ...m to have as a reference when refitting xx1800003068 3 xx1800003070 Separate the base from the swing CAUTION The axis 1 mechanical stop is accessible now Put it aside for later refitting xx1800003071 4 Continues on next page Product manual IRB 1100 307 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 308: ...nd the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing gearboxes will release axes This means the axes can fall down Make sure axes are well supported before remov ing gearboxes 3 Continues on next page 308 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 ...

Page 309: ...pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 309 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing t...

Page 310: ... swing support carefully Tip If the swing support is hard to loosen from the lower arm use a plastic hammer to knock on the swing support lightly 3 Route the upper cable package out of the swing support 4 Continues on next page 310 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 311: ... Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1900002200 Check the radial sealing on the swing Replace if damaged as described below In order to replace the radial sealing both the axis 1 mechanical stop and the axis 1 gearbox must be removed from the swing if not already removed 2 Grease 3HAC029132 001 Apply a little greas...

Page 312: ...he small circular plate with screws 6 xx1900002156 Place the large circular plate of the radial sealing fitting tool against the radial sealing and fix with six M6x50 screws 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 10 Continues on next page 312 Product manual IRB 1100 3HAC0649...

Page 313: ...re placing the radial sealing and wipe clean after the replacement 3 xx1900002157 Place the new sealing in its groove in the swing support 4 Axis 2 radial sealing assembly tool included in the radial sealing as sembly tool set 3HAC074609 001 xx1900002158 Place the dish shaped plate of the radial sealing fitting tool against the radial sealing 5 Fit the circular plate to the other side of the swing...

Page 314: ... to the lower arm Note Some robots may be fitted with separate screws and washers During replacement always use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 2 For robots with protection class IP40 Tightening torque 4 2 Nm For robots with protection class IP67 For robots with protection type Clean Room Tightening torque 4 Nm xx1900002192 Rou...

Page 315: ...ype Clean Room option 3351 4 Apply a string of the sealant Sikaflex 521FC to the joint of the swing support Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth joint If necessary add extra sealant to get a full cover joint 6 Refitting the axis 1 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wip...

Page 316: ...cing the axis 1 mechanical stop Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Mechanical stop axis 1 3HAC061947 001 Check the axis 1 mechanical stop Replace if damaged 2 Continues on next page 316 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights re...

Page 317: ...igure is fa cing the swing when putting xx1800003619 3 Refitting the base to the swing Note Action For robots with protection type Clean Room 1 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 1100 317 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the s...

Page 318: ...oom 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free brake release button assembly tool included in the special toolkit 3HAC071022 001 xx1800003040 Refit the brake release button Note Do not reconnect the connector yet Do not tighten the button yet 2 Continues on next page 318 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019...

Page 319: ... damages the motor is clean and undamaged 2 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003602 Check the cooling pad Replace if damaged 3 xx1800003085 Install the timing belt to the motor pulley and verify that the belt runs correctly in the groove of the pulley 4 Continues on next page Product manual IRB 1100 319 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved ...

Page 320: ... 5 Screw M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC063985 001 3 pcs xx1800003065 Adjusting the axis 1 timing belt tension Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 320 Product manual IRB 1...

Page 321: ...0000041 Tightening torque 3 Nm Secure the motor with the screws 4 Securing the brake release button Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free brake release button assembly tool included in the special toolkit 3HAC071022 001 xx1800003040 Tighten the brake release button using the ...

Page 322: ...abling with rear interface Insert the cable package in the base and up through the axis 1 gearbox through the rear Tip Wrap the connectors with the masking tape CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 3 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should b...

Page 323: ...tch on the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Securing the lower cable package to the axis 1 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Conti...

Page 324: ...rbox The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 2 xx1800003049 xx1800003050 Continues on next page 324 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 325: ...r robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Screw M3x8 12 9 Lafre 2C2B FC6 9 3 pcs Refit the puller cover 2 Tightening torque 1 2 Nm xx1800003043 Checking the SMB cover gasket Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free ...

Page 326: ... 2 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Tightening torque 0 3 Nm xx1800002468 Reconnect the connectors SMB P7 SMB J1 SMB J2 Tip See the number markings on the connectors for help to find the corresponding connector 3 Route and secure the cabling with cable straps CAUTION Correct cable routing is highly important If the cables are ...

Page 327: ...or interface plate Note Action For robots with protection type Clean Room 1 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 1100 327 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 328: ...ed Valid for cabling with bottom inter face option 3309 1 Gasket for base bottom 3HAC065345 001 xx1900002188 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 3 Continues on next page 328 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reser...

Page 329: ...fre 2C2B FC6 9 6 pcs Refit the connector interface plate to the base 5 Tightening torque 1 2 Nm Valid for cabling with rear inter face xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page Product manual IRB 1100 329 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 330: ...the brake release cabling and axis 1 motor connectors Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003054 Reconnect the connectors J1M BR MP1 FB1 Tip See the number markings on the connectors for help to find the corresponding connector 2 Continues on next page 330 Product man...

Page 331: ...depending on if the connector interface is located either at the rear or at the bottom of the base Note Action For robots with protection type Clean Room 1 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 1100 331 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Rep...

Page 332: ...rear 3HAC065350 001 xx1900002189 Apply grease to the cable package cover all moving area of the package 3 Apply grease to the covers that have contacting area with the cable package 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 Continues on next page 332 Product manual ...

Page 333: ...n the joints that have been opened and wipe the parts free from particles with spirit on a lint free CAUTION The IRB 1100 robot weighs 21 1 kg and can be lifted by one person 2 Attachment screws M12x25 robot installation directly on foundation quality 8 8 Raise the robot to standing and secure to the foundation with the attachment screws and washers 3 Washers 24 x 13 x 2 5 steel hard ness class 20...

Page 334: ...g air hoses The air hoses with the same number connect to the same Y shaped connector 2 xx1800002501 Reconnect the connectors J2 C1 J2 C2 Tip See the number markings on the connectors for help to find the corresponding connector 3 Securing the cable package to the swing Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from part...

Page 335: ...arts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003603 Check the cooling pad Replace if damaged as shown in the following step 3 Continues on next page Product manual IRB 1100 335 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights...

Page 336: ...motor con nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 5 Screw M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC063985 001 3 pcs xx1800002494 Continues on next page 336 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All ...

Page 337: ...e screw to the hole 8 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 9 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page Product manual IRB 1100 337 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repai...

Page 338: ...measure the timing belt tension 11 New belt 180 229 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 12 Continues on next page 338 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the swing Continued ...

Page 339: ...rs at the division point Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003029 Insert the female header of the connectors to the connector plate 2 Continues on next page Product manual IRB 1100 339 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 ...

Page 340: ...red incorrectly the cables can be damaged 4 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 5 Tightening torque 0 8 Nm xx1800002489 Refitting the swing covers Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 340 Product manual IRB 1100 3HAC064992 ...

Page 341: ... xx1800003607 Concluding procedure Note Action For robots with protection type Clean Room 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the r...

Page 342: ...via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC069056 001 Lower arm IRB 1100 4 0 58 Used with protection class IP67 3HAC074273 001 Lower arm with sealing ring IRB 1100 4 0 58 Used with protection type Clean Room 3HAC075490 001 Lower arm with sealing ring Clean Room IRB 1100 4 0 58 Continues on next page 342 Product manual IRB 1100 3HAC064992 001 Revision L Copyright...

Page 343: ...n Room Replace if damaged 3HAB3772 143 O ring on circular spline side Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAB3772 182 O ring on flexible spline side 3HAC069051 001 Swing cover Used with protection type Clean Room 3HAC075498 001 Swing cover Clean Room 3HAC069052 001 Swing support cover Used with protection type Clean Room 3HAC075500 001 Swing support c...

Page 344: ...andard toolkit on page 757 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Used for...

Page 345: ...ot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Product manual IRB 4600 If no previous reference valu...

Page 346: ... when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 4 Removing the axis 2 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts ...

Page 347: ...over 4 xx1800002489 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 re move from the plate 5 Continues on next page Product manual IRB 1100 347 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 348: ...ave as a reference when reconnecting 6 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 7 xx1800002492 Remove the swing cover 8 Continues on next page 348 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 349: ...fully lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 12 Continues on next pa...

Page 350: ...ir pressure are turned off 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 123 2 Continues on next page 350 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacin...

Page 351: ... the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB...

Page 352: ...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 123 2 xx1800002500 Disconnect the air hoses from the Y shaped con nectors 3 Continues on next page 352 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights...

Page 353: ...from the axis 2 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Produ...

Page 354: ...ots 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 123 2 xx1800003003 Remove the lower arm support cover 3 Continues on next page 354 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Re...

Page 355: ...and disconnect the connectors FB3 MP3 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 5 xx1800003006 Remove the cable bracket 6 Removing the axis 3 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 355 3HA...

Page 356: ... paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 Continues on next page 356 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 357: ...arefully lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 7 Continues on next page Product manual IRB 1100 357 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower ar...

Page 358: ...ssure are turned off 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 123 2 Continues on next page 358 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the ...

Page 359: ...upport 4 Separating the swing from the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Con...

Page 360: ...ER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 CAUTION Removing gearboxes will release axes This means the axes can...

Page 361: ...sure are turned off 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 123 2 Continues on next page Product manual IRB 1100 361 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the l...

Page 362: ... robot See Cut the paint or surface on the robot before replacing parts on page 123 2 xx1800003088 Remove the lower arm support Tip If the lower arm support is hard to loosen from the housing use a plastic hammer to knock on the lower arm support lightly 3 Separating the lower arm from the housing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressu...

Page 363: ...tact ABB for more informa tion 3 xx1800003090 Separate the lower arm from the housing Tip If the lower arm is hard to loosen from the hous ing use a plastic hammer to knock on the lower arm lightly 4 Refitting the lower arm Use these procedures to refit the lower arm Refitting the lower arm to the housing Note Action For robots with protection type Clean Room 1 Clean the joints that have been open...

Page 364: ...190 Checking the radial sealing on the lower arm support IP67 or Clean Room Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1900002202 Check the radial sealing on the lower arm support Replace if damaged as described below 2 Grease 3HAC029132 001 Apply a little grease to the new seal...

Page 365: ...port with six M6x50 screws 6 xx1900002162 Screw the screws little by little to press the sealing into place 7 Remove the assembly tool 8 Check that the sealing is undamaged and properly fitted 9 Securing the lower arm support Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on...

Page 366: ...orque 8 Nm xx1800003088 Route the cable package through the lower arm support 4 Refitting the axis 2 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 366 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair...

Page 367: ... For robots with protection type Clean Room option 3351 4 Check the O rings Replace if damaged 2 O ring on circular spline side 3HAB3772 143 xx1900002194 Continues on next page Product manual IRB 1100 367 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 368: ...ng the swing to the lower arm Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 368 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 369: ...02203 Checking the radial sealing on the swing support IP67 or Clean Room Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1900002201 Check the radial sealing on the swing support Replace if damaged as described below 2 Grease 3HAC029132 001 Apply a little grease to the new sealing wh...

Page 370: ...rt with six M6x50 screws 6 xx1900002159 Screw the screws little by little to press the sealing into place 7 Remove the assembly tool 8 Check that the sealing is undamaged and properly fitted 9 Securing the swing support Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next ...

Page 371: ...m option 3351 4 Apply a string of the sealant Sikaflex 521FC to the joint of the swing support Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth joint If necessary add extra sealant to get a full cover joint 4 Guiding the upper cable package down to the swing Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened...

Page 372: ...on type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 3 and 4 mo tors 3HAC071021 001 xx1800003604 Check the cooling pad Replace if damaged 3 Continues on next page 372 Product manual IRB 1100 3HAC064992 001 Re...

Page 373: ...rectly and fit it into the lower arm 4 Screw M4x12 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 5 Washer 3HAC063985 001 3 pcs xx1800003009 Continues on next page Product manual IRB 1100 373 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 374: ... entire screw to the hole 7 Initial referenced force for used belt 21 7 23 94 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 8 Initial referenced force for new belt 31 34 2 N Continues on next page 374 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Rep...

Page 375: ...to measure the timing belt tension 10 New belt 113 143 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 11 Continues on next page Product manual IRB 1100 375 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 376: ...ctors into the connector plate and reconnect the connectors FB3 MP3 Tip See the number markings on the connectors for help to find the corresponding connector 2 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 3 Continues on next page 376 Product manual IRB 1100 3HAC064992 001...

Page 377: ... 4 Nm xx1800003004 Securing the upper cable package to the axis 2 gearbox Note Action For robots with protection type Clean Room 1 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 1100 377 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Cont...

Page 378: ...800002500 Reconnect the air hoses in a cross pattern to the Y shaped connectors Tip See the number markings on the air hoses for help to find the corresponding air hoses The air hoses with the same number connect to the same Y shaped connector 2 xx1800002501 Reconnect the connectors J2 C1 J2 C2 Tip See the number markings on the connectors for help to find the corresponding connector 3 Continues o...

Page 379: ...obots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003603 Check the cooling pad Replace if damaged as shown in the following step 3 Continues on next ...

Page 380: ...tor con nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 5 Screw M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC063985 001 3 pcs xx1800002494 Continues on next page 380 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All ri...

Page 381: ...screw to the hole 8 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 9 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page Product manual IRB 1100 381 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair ...

Page 382: ...asure the timing belt tension 11 New belt 180 229 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 12 Continues on next page 382 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 383: ... at the division point Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003029 Insert the female header of the connectors to the connector plate 2 Continues on next page Product manual IRB 1100 383 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 5 ...

Page 384: ...ured incorrectly the cables can be damaged 4 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 5 Tightening torque 0 8 Nm xx1800002489 Refitting the covers Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 384 Product manual IRB 1100 3HAC064992 001 R...

Page 385: ...ning torque 1 2 Nm xx1800003610 Concluding procedure Note Action For robots with protection type Clean Room 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711...

Page 386: ...te Article number Spare part 3HAC069094 001 Process hub basic Used with protection type Clean Room 3HAC075509 001 Process hub basic Clean Room 3HAC069095 001 Process hub CP CS and air hose without Ethernet Used with protection type Clean Room 3HAC075510 001 Process hub Clean Room CP CS and air hose without Ethernet 3HAC069096 001 Process hub CP CS and air hose with Ethernet Continues on next page ...

Page 387: ... 4 3HAC083584 001 Motor with flange axis 6 3HAC061939 001 Timing belt axis 6 3HAC069054 001 Housing cover Used with protection type Clean Room 3HAC075501 001 Housing cover Clean Room 3HAC069061 001 Wrist cover Used with protection type Clean Room 3HAC075507 001 Wrist cover Clean Room Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAC061959 007 Gasket for housing...

Page 388: ...valid calibration method for the robot The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Used for measuring the timing belt tension Sonic tension meter Used for measuring the timing belt tension Dynamometer Included i...

Page 389: ... robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Product manual IRB 4600 If no previous reference ...

Page 390: ...e when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 4 Removing the process hub Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling parts ...

Page 391: ...following steps 3 xx1800002945 Disconnect the air hoses 4 xx1800002947 For robots with CP CS cabling Disconnect the connector J5 C1 5 J5 C2 connector assembly tool xx1800002948 For robots with Ethernet cabling Disconnect the connector J5 C2 using the tool 6 Continues on next page Product manual IRB 1100 391 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replac...

Page 392: ...e the wrist covers from both sides 3 Disconnecting the axis 5 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 rep...

Page 393: ...ower hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 393 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights res...

Page 394: ... edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 4 Continues on next page 394 Product manual IRB 1100 3H...

Page 395: ...trical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 395 3HAC064992 001 Revision L Copyright 2019 2022 ABB All ri...

Page 396: ...er unit to access the cable package locking screw on the axis 4 gearbox and then loosen the locking screw 4 xx1800003001 Disconnecting the axis 4 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 396 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights rese...

Page 397: ...pper cable package from the housing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on nex...

Page 398: ...e turned off 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 123 2 Continues on next page 398 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing ...

Page 399: ...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 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 Continues on next page Product manual IRB 1100 39...

Page 400: ...out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 6 Continues on next page 400 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 401: ...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 123 2 CAUTION Loosening timing belts will release axes This means the axes can fall down Make sure axes are well supported before loosening timing belts 3 xx1800003097 Remove the pulley cover 4 Continues on next page Product manual IRB 1100 401 ...

Page 402: ...paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 xx1900002191 Remove the screws Note Some robots may be fitted with separate screws and washers During replacement always use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 3 Continues on next page 402 Product manual ...

Page 403: ...ies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 403 3HAC064992 001 Revision L Copyright 2019 202...

Page 404: ...he plate as shown in following step 4 xx1800003005 Slide the connectors out of the connector plate and disconnect the connectors FB3 MP3 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 5 xx1800003006 Remove the cable bracket 6 Continues on next page 404 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB A...

Page 405: ...e lower arm support lightly 3 Loosening the axis 3 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 1...

Page 406: ...lt from its grooves on the motor and gearbox 6 Separating the lower arm from the housing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 406 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 407: ...e the lower arm from the housing Tip If the lower arm is hard to loosen from the hous ing use a plastic hammer to knock on the lower arm lightly 4 Removing the axis 3 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint...

Page 408: ...s means the axes can fall down Make sure axes are well supported before remov ing gearboxes 3 Continues on next page 408 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 409: ...01417 Remove the labyrinth sealing ring lightly and evenly 5 xx1800003284 Remove the screws 6 Pull out the gearbox 7 Continues on next page Product manual IRB 1100 409 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 410: ...Action For robots with protection type Clean Room 1 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 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 411: ...0 For robots with protection type Clean Room option 3351 4 Check the O rings Replace if damaged 2 O ring on circular spline side 3HAC061327 009 xx1900002196 Continues on next page Product manual IRB 1100 411 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 412: ...3x30 12 9 Lafre 2C2B FC6 9 12 pcs Secure with screws 4 Tightening torque 1 8 Nm xx1800003284 Continues on next page 412 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 413: ... to the screws and secure the labyrinth sealing ring with the screws 7 Tightening torque 0 8 Nm xx1900001425 Refitting the lower arm to the housing Note Action For robots with protection type Clean Room 1 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 1100 413 3HAC064992 001 Revision L Copyright 201...

Page 414: ...2190 Checking the radial sealing on the lower arm support IP67 or Clean Room Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1900002202 Check the radial sealing on the lower arm support Replace if damaged as described below 2 Grease 3HAC029132 001 Apply a little grease to the new sea...

Page 415: ...pport with six M6x50 screws 6 xx1900002162 Screw the screws little by little to press the sealing into place 7 Remove the assembly tool 8 Check that the sealing is undamaged and properly fitted 9 Securing the lower arm support Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues o...

Page 416: ...g torque 8 Nm xx1800003088 Route the cable package through the lower arm support 4 Securing the axis 3 motor Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 416 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair...

Page 417: ...e entire screw to the hole 3 Initial referenced force for used belt 21 7 23 94 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 4 Initial referenced force for new belt 31 34 2 N Continues on next page Product manual IRB 1100 417 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Re...

Page 418: ...02 109 Hz Use a sonic tension meter to measure the timing belt tension 6 New belt 113 143 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 7 Continues on next page 418 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 419: ...ctors into the connector plate and reconnect the connectors FB3 MP3 Tip See the number markings on the connectors for help to find the corresponding connector 2 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 3 Continues on next page Product manual IRB 1100 419 3HAC064992 001...

Page 420: ...fitting the housing Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003075 Valid for IRB 1100 4 0 475 Refit the the wrist to the housing 2 Continues on next page 420 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Repla...

Page 421: ...robots with protection class IP40 Tightening torque 1 9 Nm For robots with protection class IP67 For robots with protection type Clean Room Tightening torque 1 8 Nm xx1900002191 Refitting the axis 4 timing belt and pulley cover Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues ...

Page 422: ...ting the axis 4 motor Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Continues on next page 422 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserv...

Page 423: ... fix the timing belt 4 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003287 Orient the motor correctly and fit it into the hous ing Note Make sure the motor flange does not press on the timing belt 5 Continues on next page Product manual IRB 1100 423 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5...

Page 424: ...00003095 Remove the motor fitting tool 8 Adjusting the axis 4 timing belt tension Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 424 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housin...

Page 425: ...ooking to the eye bolt 4 Used belt 20 09 22 05 N Pull the dynamometer to make the tension falling in the allowed force range Note Pay attention to the force application direction 5 New belt 28 7 31 5 N Continues on next page Product manual IRB 1100 425 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 426: ...n 3350 670 For robots with protection type Clean Room option 3351 4 Rubber sealing washer on housing 3HAC064147 001 Tightening torque 2 Nm Refitting the upper cable harness through the axis 4 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 426 Product man...

Page 427: ...4 gearbox Tip Wrap the connectors with the masking tape CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 2 Securing the upper cable package to the axis 4 gearbox Note Action For robots with protection type Clean Room 1 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 ...

Page 428: ... The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 2 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page 428 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued ...

Page 429: ... 4 Nm Valid for IRB 1100 4 0 475 xx1800003031 Note If there is locking liquid residues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for IRB 1100 4 0 58 xx1800003001 Continues on next page Product manual IRB 1100 429 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the housing Continued...

Page 430: ...ype Clean Room option 3351 4 Rubber sealing washer on extender unit 3HAC067995 001 Tightening torque 2 Nm xx1800003000 Securing the upper cable package to the housing Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 430 Product manual IRB 1100 3HAC064992 001 Revis...

Page 431: ...ng is highly important If the cables are routed and secured incorrectly the cables can be damaged 3 Reconnecting the axis 4 motor connectors Note Action For robots with protection type Clean Room 1 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 1100 431 3HAC064992 001 Revision L Copyright 2019 2022 ...

Page 432: ...Refitting the axis 6 motor Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Continues on next page 432 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights r...

Page 433: ...he connectors MP5 and MP6 accessible from wrist side 3 Screw M3x12 12 9 Lafre 2C2B FC6 9 3 pcs xx1800002996 Refit the screws and washers Note Do not tighten the screws yet 4 xx1800003024 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 5 Continues on next page Product manual IRB 1100 433 3HAC064992 001 Revision L Copyright 2019 2022 ABB ...

Page 434: ...itial referenced force for new belt 12 8 14 xx1900000026 Tightening torque 1 4 Nm xx1800002995 Secure the motor with the screws 8 Used belt 81 3 86 9 Hz Use a sonic tension meter to measure the timing belt tension 9 New belt 90 114 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 10 Continues on next page 434 Product manual IRB 11...

Page 435: ...nnector 2 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 3 Insert the cabling and connectors into the wrist 4 Reconnecting the axis 5 motor connectors Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from...

Page 436: ...he wrist 4 Refitting the process hub Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Gasket for process hub 3HAC065352 001 xx1900002187 For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 3351 4 Check the gasket Replace if damaged 2 C...

Page 437: ...5 C2 connector assembly tool in cluded in the special toolkit 3HAC071022 001 xx1800002948 For robots with Ethernet cabling Reconnect the connector J5 C2 using the tool 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 Continues on next page Product manual IRB 1100 437 3HAC0...

Page 438: ...free xx1900002177 For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 3351 4 Check the gaskets Replace if damaged 2 Apply grease to the cable package cover all moving area of the package 3 Apply grease to the covers that have contacting area with the cable package 4 Continues on next page 438 Product manual IRB 1100 3HAC064992 001 Revision L Copy...

Page 439: ... See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 Product manual IRB 1100 439 3HAC064992 001 Revi...

Page 440: ... 1100 4 0 58 has an extender unit connecting the housing and wrist which is located as shown in the figure xx1800002476 Continues on next page 440 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist ...

Page 441: ...ithout Ethernet Used with protection type Clean Room 3HAC075510 001 Process hub Clean Room CP CS and air hose without Ethernet 3HAC069096 001 Process hub CP CS and air hose with Ethernet Used with protection type Clean Room 3HAC075511 001 Process hub Clean Room CP CS and air hose with Ethernet Used for IRB 1100 4 0 58 3HAC069037 001 Extender unit Used for IRB 1100 4 0 58 Used with protection type ...

Page 442: ...e Clean Room 3HAC075501 001 Housing cover Clean Room 3HAC069061 001 Wrist cover Used with protection type Clean Room 3HAC075507 001 Wrist cover Clean Room 3HAC069057 001 Lower arm cover Used with protection type Clean Room 3HAC075503 001 Lower arm cover Clean Room 3HAC069059 001 Lower arm support cover Used with protection type Clean Room 3HAC075505 001 Lower arm support cover Clean Room Used with...

Page 443: ... Standard toolkit on page 757 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Used ...

Page 444: ... to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Product manual ...

Page 445: ...isassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 4 Removing the process hub Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 r...

Page 446: ...g steps 3 xx1800002945 Disconnect the air hoses 4 xx1800002947 For robots with CP CS cabling Disconnect the connector J5 C1 5 J5 C2 connector assembly tool xx1800002948 For robots with Ethernet cabling Disconnect the connector J5 C2 using the tool 6 Continues on next page 446 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the ...

Page 447: ...ist covers from both sides 3 Disconnecting the axis 5 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 p...

Page 448: ...raulic pressure and air pressure are turned off 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 123 2 Continues on next page 448 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 ...

Page 449: ...en disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 4 Continues on next page Product manual IRB 1100 449 3HAC064992...

Page 450: ...th 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 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 Continues on next page 450 Product manual IRB 1100 3HAC064...

Page 451: ... Remove the screws and washers 5 Carefully lift out the motor 6 xx1800003295 Remove the timing belt from its groove on the motor 7 Continues on next page Product manual IRB 1100 451 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 452: ...he paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 xx1800003031 Valid for IRB 1100 4 0 475 Access the cable package locking screw on the axis 4 gearbox from the wrist and then loosen the locking screw 3 Continues on next page 452 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reser...

Page 453: ...all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 453 3HAC064992 001 Revision L Copyright...

Page 454: ...e and air pressure are turned off 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 123 2 Continues on next page 454 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 R...

Page 455: ... off 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 123 2 Continues on next page Product manual IRB 1100 455 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit an...

Page 456: ...ith 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 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 Continues on next page 456 Product manual IRB 1100 3HAC06...

Page 457: ...motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 6 Continues on next page Product manual IRB 1100 457 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Contin...

Page 458: ...th 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 123 2 CAUTION Loosening timing belts will release axes This means the axes can fall down Make sure axes are well supported before loosening timing belts 3 xx1800003097 Remove the pulley cover 4 Continues on next page 458 Product manual IRB 1100 3HAC0649...

Page 459: ...ge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 xx1900002191 Remove the screws Note Some robots may be fitted with separate screws and washers During replacement always use the same screws and washers that are fitted on the robot at delivery Contact ABB for more informa tion 3 Continues on next page Product manual IRB 1100 459...

Page 460: ...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 123 2 CAUTION Removing gearboxes will release axes This means the axes can fall down Make sure axes are well supported before remov ing gearboxes 3 Continues on next page 460 Product manu...

Page 461: ... pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 461 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair...

Page 462: ...ots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free O ring 3HAB3772 115 xx1900002193 For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 3351 4 Check the O ring Replace if damaged 2 Continues on next page 462 Product manual IRB 1100 3HAC064992 001 Revision ...

Page 463: ...Lafre 2C2B FC6 9 16 pcs Refit the extender unit to the wrist 4 Tightening torque 2 Nm xx1800003311 Refitting the axis 4 gearbox Note Action For robots with protection type Clean Room 1 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 1100 463 3HAC064992 001 Revision L Copyright 2019 2022 ABB All right...

Page 464: ...ots with protection type Clean Room option 3351 4 Check the O rings Replace if damaged 2 O ring on circular spline side 3HAC061327 009 xx1900002198 Continues on next page 464 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 465: ...r 3 Valid for IRB 1100 4 0 475 xx1800003313 Valid for IRB 1100 4 0 58 xx1800003312 Screw M3x30 12 9 Lafre 2C2B FC6 9 12 pcs Secure with screws 4 Tightening torque 1 8 Nm Continues on next page Product manual IRB 1100 465 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 466: ...es with spirit on a lint free xx1800003075 Valid for IRB 1100 4 0 475 Refit the the wrist to the housing 2 xx1800003100 Valid for IRB 1100 4 0 58 Refit the extender unit and wrist to the housing 3 Continues on next page 466 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 467: ...ction type Clean Room Tightening torque 1 8 Nm xx1900002191 Refitting the axis 4 timing belt and pulley cover Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003098 Install the timing belt to the gearbox pulley and verify that the belt runs correctly in the groove of the pulley 2...

Page 468: ... the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 3 and 4 mo tors 3HAC071021 001 xx1800003605 Check the cooling pad Replace if damaged 3 Continues on next page 468 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 ...

Page 469: ...regard to the encircled motor con nector xx1800003287 Orient the motor correctly and fit it into the hous ing Note Make sure the motor flange does not press on the timing belt 5 xx1800003617 Install the timing belt to the motor pulley 6 Continues on next page Product manual IRB 1100 469 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit...

Page 470: ... 8 Adjusting the axis 4 timing belt tension Note Action For robots with protection type Clean Room 1 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 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 471: ...o the eye bolt 4 Used belt 20 09 22 05 N Pull the dynamometer to make the tension falling in the allowed force range Note Pay attention to the force application direction 5 New belt 28 7 31 5 N Continues on next page Product manual IRB 1100 471 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 472: ...70 For robots with protection type Clean Room option 3351 4 Rubber sealing washer on housing 3HAC064147 001 Tightening torque 2 Nm Refitting the upper cable harness through the axis 4 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 472 Product manual IRB ...

Page 473: ...x Tip Wrap the connectors with the masking tape CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 2 Securing the upper cable package to the axis 4 gearbox Note Action For robots with protection type Clean Room 1 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 1100...

Page 474: ...le protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 2 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page 474 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 475: ...lid for IRB 1100 4 0 475 xx1800003031 Note If there is locking liquid residues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for IRB 1100 4 0 58 xx1800003001 Continues on next page Product manual IRB 1100 475 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist C...

Page 476: ...n Room option 3351 4 Rubber sealing washer on extender unit 3HAC067995 001 Tightening torque 2 Nm xx1800003000 Securing the upper cable package to the housing Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 476 Product manual IRB 1100 3HAC064992 001 Revision L Co...

Page 477: ...ghly important If the cables are routed and secured incorrectly the cables can be damaged 3 Reconnecting the axis 4 motor connectors Note Action For robots with protection type Clean Room 1 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 1100 477 3HAC064992 001 Revision L Copyright 2019 2022 ABB All ...

Page 478: ...g the axis 5 motor Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Continues on next page 478 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved ...

Page 479: ...ors MP5 and MP6 accessible from wrist side 3 Screw M3x12 12 9 Lafre 2C2B FC6 9 3 pcs xx1800003291 Refit the screws and washers Note Do not tighten the screws yet 4 xx1800003292 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 5 Continues on next page Product manual IRB 1100 479 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights...

Page 480: ...ferenced force for new belt 19 4 21 2 N xx1900000027 Tightening torque 1 4 Nm xx1800003290 Secure the motor with the screws 8 Used belt 151 162 Hz Use a sonic tension meter to measure the timing belt tension 9 New belt 167 213 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 10 Continues on next page 480 Product manual IRB 1100 3H...

Page 481: ...he motor is clean and undamaged 2 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003023 Orient the motor correctly and fit it into the lower arm Tip Leave the connectors FB5 and FB6 accessible from the process hub and the connectors MP5 and MP6 accessible from wrist side 3 Continues on next page Product manual IRB 1100 481 3HAC064...

Page 482: ...stment screw to the motor Note Do not insert the entire screw to the hole 6 Initial referenced force for used belt 8 96 9 8 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 7 Initial referenced force for new belt 12 8 14 xx1900000026 Continues on next page 482 Product manual IRB 1100 3HAC064992 001 Revision L Copyr...

Page 483: ...he motor screws and readjust 10 xx1900000007 Remove the adjustment screw from the motor 11 Reconnecting the axis 6 motor connectors Note Action For robots with protection type Clean Room 1 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 1100 483 3HAC064992 001 Revision L Copyright 2019 2022 ABB All r...

Page 484: ...lean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003025 Reconnect the connectors FB5 MP5 Tip See the number markings on the connectors for help to find the corresponding connector 2 Route and secure the cabling with cable straps CAUTION Correct cable routing is highly important If the cables are routed and secured incorrectl...

Page 485: ... robots with protection type Clean Room option 3351 4 Check the gasket Replace if damaged 2 xx1800002945 Reconnect the air hoses in a cross pattern Tip See the number markings on the air hoses for help to find the corresponding air hoses The air hoses with the same number connect to the same Y shaped connector 3 Continues on next page Product manual IRB 1100 485 3HAC064992 001 Revision L Copyright...

Page 486: ...l 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 Screw M3x8 12 9 Lafre 2C2B FC6 9 4 pcs Refit the cover 7 Tightening torque 1 2 Nm xx1800002944 Continues on next page 486 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repa...

Page 487: ...8 12 9 Lafre 2C2B FC6 9 Refit the covers Wrist covers Lower arm support cover Housing cover 5 Tightening torque 1 2 Nm xx1800003612 Concluding procedure Note Action For robots with protection type Clean Room 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from p...

Page 488: ... all safety requirements are met when performing the first test run 3 488 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the extender unit and wrist Continued ...

Page 489: ...B Business Portal www abb com myABB Note Article number Spare part 3HAC083589 001 Motor with flange axis 1 3HAC061935 001 Timing belt axis 2 Standard configuration used for robots with rear connector inter face 3HAC060463 001 Base bottom cover Used for robots with bottom con nector interface 3HAC070312 001 Base rear cover Continues on next page Product manual IRB 1100 489 3HAC064992 001 Revision L...

Page 490: ... piece each time 3HAC071020 001 Cooling pad for axis 1 and 2 mo tors 9x4 3x1 Steel 3HAC063985 001 Washer Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 757 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibrati...

Page 491: ... is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Product manual IRB 4600 If no previous reference values...

Page 492: ... before replacing parts on page 123 4 Putting the robot on its side Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 part...

Page 493: ...erface plate Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual I...

Page 494: ...N There are cabling attached to the cover The cover cannot be removed completely until the connectors are removed 3 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page 494 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 495: ...hat all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 495 3HAC064992 001 Revision L Copyr...

Page 496: ...s for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page 496 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ...

Page 497: ...Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 497 3...

Page 498: ...aint 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 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 Continues on next page 498 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All...

Page 499: ...t the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 6 Continues on next page Product manual IRB 1100 499 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 500: ... been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003602 Check the cooling pad Replace if damaged 3 Continues on next page 500 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights res...

Page 501: ...ase 4 xx1800003615 Install the timing belt to the motor pulley 5 Screw M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC063985 001 3 pcs xx1800003065 Continues on next page Product manual IRB 1100 501 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 502: ...re removed Pay attention to the force application direction 3 New belt 83 2 90 8 N for reference only xx1900000041 Tightening torque 3 Nm Secure the motor with the screws 4 Securing the lower cable package to the base Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Screw M2 5x6 12 9 La...

Page 503: ... For robots with protection type Clean Room option 3351 4 Check the gasket Replace if damaged Valid for cabling with bottom inter face option 3309 1 Gasket for base bottom 3HAC065345 001 xx1900002188 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 3 Continues on next page Pro...

Page 504: ...2C2B FC6 9 6 pcs Refit the connector interface plate to the base 5 Tightening torque 1 2 Nm Valid for cabling with rear inter face xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page 504 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 motor Continued ...

Page 505: ...th protection type Clean Room option 3351 4 Check the gasket Replace if damaged Valid for cabling with bottom inter face option 3309 1 Gasket for base rear 3HAC065350 001 xx1900002189 Apply grease to the cable package cover all moving area of the package 3 Apply grease to the covers that have contacting area with the cable package 4 Route and secure the cabling with cable straps CAUTION Correct ca...

Page 506: ...e joints that have been opened and wipe the parts free from particles with spirit on a lint free CAUTION The IRB 1100 robot weighs 21 1 kg and can be lifted by one person 2 Attachment screws M12x25 robot installation directly on foundation quality 8 8 Raise the robot to standing and secure to the foundation with the attachment screws and washers 3 Washers 24 x 13 x 2 5 steel hard ness class 200HV ...

Page 507: ...r all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 Product manual IRB 1100 507 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 1 Replacing the axis 1 ...

Page 508: ...b com myABB Note Article number Spare part 3HAC083588 001 Motor with flange axis 2 3HAC061935 001 Timing belt axis 2 3HAC069051 001 Swing cover Used with protection type Clean Room 3HAC075498 001 Swing cover Clean Room 3HAC069052 001 Swing support cover Used with protection type Clean Room 3HAC075500 001 Swing support cover Clean Room Continues on next page 508 Product manual IRB 1100 3HAC064992 0...

Page 509: ...it Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Used for measuring the timing belt tension Sonic ...

Page 510: ... is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Product manual IRB 4600 If no previous reference values...

Page 511: ...ot before replacing parts on page 123 4 Removing the axis 2 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 ...

Page 512: ...er 4 xx1800002489 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 re move from the plate 5 Continues on next page 512 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 2 Replacing the axis 2 motor Continued ...

Page 513: ...e as a reference when reconnecting 6 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 7 xx1800002492 Remove the swing cover 8 Continues on next page Product manual IRB 1100 513 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 2 Replacing the axis 2 motor Continued ...

Page 514: ...ully lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 12 Continues on next pag...

Page 515: ...nt edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 xx1800003026 Loosen the cooling pad bracket screws on the motor flange 3 Use a plastic sheet with caution to remove the cooling pad together with the bracket from the motor Pay attention not to scratch the motor or damage the pad 4 Continues on next page Product manual IRB 1...

Page 516: ... motor flange and the screw holes are aligned Screw M3x5 12 9 Lafre 2C2B FC6 9 2 pcs Refit the cooling pad bracket 3 Tightening torque 1 2 Nm xx1800003026 Refitting the axis 2 motor Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without d...

Page 517: ...rt 3 Screw M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 4 Washer 3HAC063985 001 3 pcs xx1800002494 xx1800003028 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 5 Continues on next page Product manual IRB 1100 517 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 ...

Page 518: ...dheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 7 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Tightening torque 3 5 Nm xx1800002493 Secure the motor with the screws 8 Continues on next page 518 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 2 Replacing the axis 2 m...

Page 519: ... the number markings on the connectors for help to find the corresponding connector 12 Reconnecting the connector J2 FB2 Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800002491 Insert the female header of the J2 FB2 connector to the connector plate 2 Continues on next page Product...

Page 520: ...es are routed and secured incorrectly the cables can be damaged 5 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 6 Tightening torque 0 8 Nm xx1800002489 Refitting the swing covers Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 520 Product manua...

Page 521: ...1800003607 Concluding procedure Note Action For robots with protection type Clean Room 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robo...

Page 522: ...ABB Note Article number Spare part 3HAC083587 001 Motor with flange axis 3 3HAC061936 001 Timing belt axis 3 3HAC069057 001 Lower arm cover Used with protection type Clean Room 3HAC075503 001 Lower arm cover Clean Room 3HAC069059 001 Lower arm support cover Used with protection type Clean Room 3HAC075505 001 Lower arm support cover Clean Room Continues on next page 522 Product manual IRB 1100 3HAC...

Page 523: ...ection Standard toolkit on page 757 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply...

Page 524: ... is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Product manual IRB 4600 If no previous reference values...

Page 525: ...e replacing parts on page 123 4 Disconnecting the axis 3 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 replacin...

Page 526: ... plate as shown in following step 4 xx1800003005 Slide the connectors out of the connector plate and disconnect the connectors FB3 MP3 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 5 xx1800003006 Remove the cable bracket 6 Continues on next page 526 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All...

Page 527: ...d the paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 Continues on next page Product manual IRB 1100 527 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair ...

Page 528: ...efully lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 7 Continues on next page 528 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 3 Replacing the axis 3 mot...

Page 529: ... with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Continues on next page Product manual IRB 1100 529 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 3 Replacing the axis 3 motor...

Page 530: ...ed motor con nector xx1800003021 Orient the motor correctly and fit it into the lower arm 4 Screw M4x12 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 5 Washer 3HAC063985 001 3 pcs xx1800003009 Continues on next page 530 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 3 Replacing the axis 3 moto...

Page 531: ...entire screw to the hole 7 Initial referenced force for used belt 21 7 23 94 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 8 Initial referenced force for new belt 31 34 2 N Continues on next page Product manual IRB 1100 531 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 3 Repl...

Page 532: ...o measure the timing belt tension 10 New belt 113 143 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 11 Continues on next page 532 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 3 Replacing the axis 3 motor Continued ...

Page 533: ...ors into the connector plate and reconnect the connectors FB3 MP3 Tip See the number markings on the connectors for help to find the corresponding connector 2 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 3 Continues on next page Product manual IRB 1100 533 3HAC064992 001 R...

Page 534: ...Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1900002179 For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 3351 4 Check the gaskets Replace if damaged 2 Apply grease to the cable package cover all moving area of the package 3 Continues on next page 534 Product manual IRB 1100 3HAC0649...

Page 535: ...s that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 Product manual IRB 1100 ...

Page 536: ...BB Note Article number Spare part 3HAC083586 001 Motor with flange axis 4 3HAC061937 001 Timing belt axis 4 3HAC069054 001 Housing cover Used with protection type Clean Room 3HAC075501 001 Housing cover Clean Room Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAC061959 007 Gasket for housing cover Continues on next page 536 Product manual IRB 1100 3HAC064992 00...

Page 537: ... on page 757 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibra tion Used to release the motor brakes 24 VDC power supply Included in the specia...

Page 538: ... is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Product manual IRB 4600 If no previous reference values...

Page 539: ...e replacing parts on page 123 4 Disconnecting the axis 4 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 replacin...

Page 540: ...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 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 Continues on next page 540 Product manual IRB 1100 3HAC064992 001 Revision L ...

Page 541: ...t the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad 6 Continues on next page Product manual IRB 1100 541 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 542: ... been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 3 and 4 mo tors 3HAC071021 001 xx1800003605 Check the cooling pad Replace if damaged 3 Continues on next page 542 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights res...

Page 543: ...w in regard to the encircled motor con nector xx1800003287 Orient the motor correctly and fit it into the hous ing Note Make sure the motor flange does not press on the timing belt 5 xx1800003617 Install the timing belt to the motor pulley 6 Continues on next page Product manual IRB 1100 543 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 m...

Page 544: ...g tool 8 Adjusting the axis 4 timing belt tension Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 544 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 545: ...king to the eye bolt 4 Used belt 20 09 22 05 N Pull the dynamometer to make the tension falling in the allowed force range Note Pay attention to the force application direction 5 New belt 28 7 31 5 N Continues on next page Product manual IRB 1100 545 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 4 Replacing the axis 4 motor Continued ...

Page 546: ...67 option 3350 670 For robots with protection type Clean Room option 3351 4 Rubber sealing washer on housing 3HAC064147 001 Tightening torque 2 Nm Reconnecting the axis 4 motor connectors Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 546 Product manual IRB 1100...

Page 547: ... protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Gasket for housing cover 3HAC061959 007 xx1900002180 For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 3351 4 Check the gasket Replace if damaged 2 Continues on next page Product manual IRB 1100 547 3HAC064992 0...

Page 548: ...ean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 5...

Page 549: ... com myABB Note Article number Spare part 3HAC083585 001 Motor with flange axis 5 3HAC061938 001 Timing belt axis 5 3HAC069061 001 Wrist cover Used with protection type Clean Room 3HAC075507 001 Wrist cover Clean Room Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAC061959 009 Gasket for wrist cover Continues on next page Product manual IRB 1100 549 3HAC064992 ...

Page 550: ...nnector if the Ethernet cabling is equipped J5 C2 connector assembly tool Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease 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 tab...

Page 551: ...an be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the motor Use these procedures to remove the axis 5 motor Preparations before removing the axis 5 motor Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the r...

Page 552: ...ean 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 123 2 xx1800002944 Remove the screws and carefully open the cover CAUTION Be aware of the cabling that is attached to the cover 3 Removing the wrist cover Note Action DANGER Make sure that all supplies for electrical powe...

Page 553: ...5 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product ma...

Page 554: ...ith 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 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 Continues on next page 554 Product manual IRB 1100 3HAC06...

Page 555: ...03291 Remove the screws and washers 5 Carefully lift out the motor 6 xx1800003292 Remove the timing belt from its groove on the motor 7 Continues on next page Product manual IRB 1100 555 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 7 5 Replacing the axis 5 motor Continued ...

Page 556: ...ient the motor according to the figure below in regard to the encircled motor con nector xx1800003296 Orient the motor correctly and fit it into the wrist Tip Leave the connectors FB5 and FB6 accessible from the process hub and the connectors MP5 and MP6 accessible from wrist side 3 Screw M3x12 12 9 Lafre 2C2B FC6 9 3 pcs xx1800003291 Refit the screws and washers Note Do not tighten the screws yet...

Page 557: ...crew to the hole 6 Initial referenced force for used belt 13 58 14 84 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 7 Initial referenced force for new belt 19 4 21 2 N xx1900000027 Continues on next page Product manual IRB 1100 557 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 ...

Page 558: ...sen the motor screws and readjust 10 xx1900000008 Remove the adjustment screw from the motor 11 Reconnecting the axis 5 motor connectors Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 558 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB ...

Page 559: ...ype Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Gasket for wrist cover 3HAC061959 009 xx1900002181 For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 3351 4 Check the gasket Replace if damaged 2 Apply grease to the cable package cover all moving area of the package 3 Apply...

Page 560: ... 3HAC065352 001 xx1900002187 For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 3351 4 Check the gasket Replace if damaged 2 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 3 Continues on next page 560 Product manual IRB 11...

Page 561: ...he robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 Product manual IRB 1100 561 3HAC064992 001 Revision L Copyright 2019 2022 ABB All...

Page 562: ...myABB Note Article number Spare part 3HAC083584 001 Motor with flange axis 6 3HAC061939 001 Timing belt axis 6 3HAC069061 001 Wrist cover Used with protection type Clean Room 3HAC075507 001 Wrist cover Clean Room Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAC061959 009 Gasket for wrist cover Continues on next page 562 Product manual IRB 1100 3HAC064992 001 R...

Page 563: ...nnector if the Ethernet cabling is equipped J5 C2 connector assembly tool Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease 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 tab...

Page 564: ...an be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the motor Use these procedures to remove the axis 6 motor Preparations before removing the axis 6 motor Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the r...

Page 565: ...ean 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 123 2 xx1800002944 Remove the screws and carefully open the cover CAUTION Be aware of the cabling that is attached to the cover 3 Removing the wrist covers Note Action DANGER Make sure that all supplies for electrical pow...

Page 566: ...nnectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page 566 Product manual I...

Page 567: ...ge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 4 Continues on next page Product manual IRB 1100 567 3HAC0...

Page 568: ... 6 motor Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Continues on next page 568 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5...

Page 569: ... connectors MP5 and MP6 accessible from wrist side 3 Screw M3x12 12 9 Lafre 2C2B FC6 9 3 pcs xx1800002996 Refit the screws and washers Note Do not tighten the screws yet 4 xx1800003024 Install the timing belt to the pulleys and verify that the belt runs correctly in the grooves of the pul leys 5 Continues on next page Product manual IRB 1100 569 3HAC064992 001 Revision L Copyright 2019 2022 ABB Al...

Page 570: ...al referenced force for new belt 12 8 14 xx1900000026 Tightening torque 1 4 Nm xx1800002995 Secure the motor with the screws 8 Used belt 81 3 86 9 Hz Use a sonic tension meter to measure the timing belt tension 9 New belt 90 114 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 10 Continues on next page 570 Product manual IRB 1100 ...

Page 571: ...g connector 2 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 3 Insert the cabling and connectors into the wrist 4 Refitting the wrist covers Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles...

Page 572: ... wrist covers 5 Tightening torque 1 2 Nm xx1800002949 Refitting the process hub Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Gasket for process hub 3HAC065352 001 xx1900002187 For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 335...

Page 573: ...om 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test ...

Page 574: ... with protection classes IP40 and IP67 3HAC075521 001 Lower cable harness basic Used with protection type Clean Room 3HAC075514 001 Lower cable harness basic Clean Room Used with protection classes IP40 and IP67 3HAC075522 001 Lower cable harness CP CS and air hose without Ethernet Used with protection type Clean Room 3HAC075515 001 Lower cable harness Clean Room CP CS and air hose without Ether n...

Page 575: ...HAC060463 001 Base bottom cover Used for robots with bottom con nector interface 3HAC070312 001 Base rear cover Used for robots with bottom con nector interface Used with protection type Clean Room 3HAC075513 001 Base rear cover Clean Room Used for robots with bottom con nector interface 3HAC070313 001 Base adapter Used for robots with bottom con nector interface Used with protection type Clean Ro...

Page 576: ...mo tors 9x4 3x1 Steel 3HAC063985 001 Washer Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 757 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during ca...

Page 577: ...to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Product manual IRB 4600 If no previous reference values exi...

Page 578: ...t before replacing parts on page 123 4 Removing the axis 2 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 o...

Page 579: ...r 4 xx1800002489 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 re move from the plate 5 Continues on next page Product manual IRB 1100 579 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 580: ... as a reference when reconnecting 6 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 7 xx1800002492 Remove the swing cover 8 Continues on next page 580 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 581: ...lly lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 12 Continues on next page...

Page 582: ...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 123 2 xx1800003032 Access the cable package locking screw on the axis 1 gearbox from the swing and then loosen the locking screw 3 Remove the locking screw 4 Continues on next page 582 Product manual IRB 1100 3HAC064992 001 Revisi...

Page 583: ...97 Disconnect the connectors J2 FB3 4 5 6 J2 MP3 4 5 6 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 3 xx1800002498 Snap loose and remove the female head of the connectors from the connector plate 4 Separating the cable package from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressu...

Page 584: ... Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 xx1800002500 Disconnect the air hoses from the Y shaped con nectors 3 ...

Page 585: ...at all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 CAUTION The IRB 1100 robot weighs 21 1 kg and can be lifted by one person 3 Continu...

Page 586: ...rned off 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 49 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 123 3...

Page 587: ...ore disconnecting them to have as a reference when reconnecting 5 Remove the SMB cover completely from the base 6 Opening the connector interface plate Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassemblin...

Page 588: ... There are cabling attached to the cover The cover cannot be removed completely until the connectors are removed 3 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page 588 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 589: ...sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 589 3HAC064992 001 Revision L...

Page 590: ...cabling with bottom interface option 3309 1 Remove the base rear cover 4 xx1800003036 Disconnect the earth cable 5 Remove the connector plate 6 Continues on next page 590 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 591: ...Note Action xx1800003037 Continues on next page Product manual IRB 1100 591 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 592: ...se button assembly tool included in the special toolkit 3HAC071022 001 xx1800003040 Remove the brake release button from the base using the tool 9 Disconnecting axis 1 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 592 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 20...

Page 593: ...e when reconnecting 3 Separating the cable package from the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 o...

Page 594: ...N 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 123 2 xx1800003043 Remove the pulley cover 3 Continues on next page 594 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Repl...

Page 595: ...ing parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 xx1800003044 Pull out the lower cable package from the axis 1 gearbox 3 xx1800003045 Pull out the lower cable package from the base 4 xx1800003046 Remove the pulley cover from the lower cable package 5 Continues on next page Product manual IRB 1100 595 3HAC064992 001 Revision L Copyright 2019 2022...

Page 596: ...the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 xx1800003064 Loosen the screws and move the motor slightly to slacken the timing belt 4 Continues on next page 596 Product manual IRB 1100 3HAC064992 001 Revision L Copyright ...

Page 597: ...e casting Pay attention not to scratch the casting or damage the pad 6 xx1800003066 Remove the timing belt from its groove on the motor 7 Removing the axis 1 timing belt Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 597 3HAC064992 001 Revision L Copyright 2019 2022 ABB All righ...

Page 598: ...e the timing belt from its groove on the gearbox 4 Separating the base from the swing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 bef...

Page 599: ... have as a reference when refitting xx1800003068 3 xx1800003070 Separate the base from the swing CAUTION The axis 1 mechanical stop is accessible now Put it aside for later refitting xx1800003071 4 Continues on next page Product manual IRB 1100 599 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 600: ...he paint edge when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing gearboxes will release axes This means the axes can fall down Make sure axes are well supported before remov ing gearboxes 3 Continues on next page 600 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repa...

Page 601: ... a lint free xx1900002200 Check the radial sealing on the swing Replace if damaged as described below In order to replace the radial sealing both the axis 1 mechanical stop and the axis 1 gearbox must be removed from the swing if not already removed 2 Grease 3HAC029132 001 Apply a little grease to the new sealing when re placing the radial sealing and wipe clean after the replacement 3 Continues o...

Page 602: ...all circular plate with screws 6 xx1900002156 Place the large circular plate of the radial sealing fitting tool against the radial sealing and fix with six M6x50 screws 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 10 Continues on next page 602 Product manual IRB 1100 3HAC064992 00...

Page 603: ...afre 2C2B FC6 9 12 pcs Secure with screws 3 Tightening torque 1 6 Nm xx1800003073 Placing the axis 1 mechanical stop Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Mechanical stop axis 1 3HAC061947 001 Check the axis 1 mechanical stop Replace if damaged 2 Continues on next page Produc...

Page 604: ...e is fa cing the swing when putting xx1800003619 3 Refitting the base to the swing Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 604 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis ...

Page 605: ... Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free brake release button assembly tool included in the special toolkit 3HAC071022 001 xx1800003040 Refit the brake release button Note Do not reconnect the connector yet Do not tighten the button yet 2 Continues on next page Product manual IRB 1100 605 3HAC064992 001 Revision L Copyright 2019 2022...

Page 606: ...ages the motor is clean and undamaged 2 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003602 Check the cooling pad Replace if damaged 3 xx1800003085 Install the timing belt to the motor pulley and verify that the belt runs correctly in the groove of the pulley 4 Continues on next page 606 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Re...

Page 607: ...crew M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC063985 001 3 pcs xx1800003065 Adjusting the axis 1 timing belt tension Note Action For robots with protection type Clean Room 1 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 1100 607 ...

Page 608: ...041 Tightening torque 3 Nm Secure the motor with the screws 4 Securing the brake release button Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free brake release button assembly tool included in the special toolkit 3HAC071022 001 xx1800003040 Tighten the brake release button using the tool...

Page 609: ...g with rear interface Insert the cable package in the base and up through the axis 1 gearbox through the rear Tip Wrap the connectors with the masking tape CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 3 Cable protection tube orientation use the encircled notch on the cable protection tube as a refer ence when inserting the cable package which should be at ...

Page 610: ...n the cable protection tube as a refer ence when inserting the cable package which should be at the opposite direction to the locking screw hole on the gearbox xx1800003048 Securing the lower cable package to the axis 1 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues ...

Page 611: ... The cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 2 xx1800003049 xx1800003050 Continues on next page Product manual IRB 1100 611 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 612: ...bots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Screw M3x8 12 9 Lafre 2C2B FC6 9 3 pcs Refit the puller cover 2 Tightening torque 1 2 Nm xx1800003043 Checking the SMB cover gasket Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from...

Page 613: ...lean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Tightening torque 0 3 Nm xx1800002468 Reconnect the connectors SMB P7 SMB J1 SMB J2 Tip See the number markings on the connectors for help to find the corresponding connector 3 Route and secure the cabling with cable straps CAUTION Correct cable routing is highly important If the cables are rout...

Page 614: ...terface plate Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 614 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 615: ...lid for cabling with bottom inter face option 3309 1 Gasket for base bottom 3HAC065345 001 xx1900002188 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 3 Continues on next page Product manual IRB 1100 615 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5...

Page 616: ...C2B FC6 9 6 pcs Refit the connector interface plate to the base 5 Tightening torque 1 2 Nm Valid for cabling with rear inter face xx1800003034 Valid for cabling with bottom inter face option 3309 1 xx1800003055 Continues on next page 616 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 617: ...rake release cabling and axis 1 motor connectors Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003054 Reconnect the connectors J1M BR MP1 FB1 Tip See the number markings on the connectors for help to find the corresponding connector 2 Continues on next page Product manual IRB 1...

Page 618: ...ding on if the connector interface is located either at the rear or at the bottom of the base Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 618 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacin...

Page 619: ... 3HAC065350 001 xx1900002189 Apply grease to the cable package cover all moving area of the package 3 Apply grease to the covers that have contacting area with the cable package 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 Continues on next page Product manual IRB 1100...

Page 620: ... joints that have been opened and wipe the parts free from particles with spirit on a lint free CAUTION The IRB 1100 robot weighs 21 1 kg and can be lifted by one person 2 Attachment screws M12x25 robot installation directly on foundation quality 8 8 Raise the robot to standing and secure to the foundation with the attachment screws and washers 3 Washers 24 x 13 x 2 5 steel hard ness class 200HV T...

Page 621: ...r hoses The air hoses with the same number connect to the same Y shaped connector 2 xx1800002501 Reconnect the connectors J2 C1 J2 C2 Tip See the number markings on the connectors for help to find the corresponding connector 3 Securing the cable package to the swing Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particle...

Page 622: ...free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003603 Check the cooling pad Replace if damaged as shown in the following step 3 Continues on next page 622 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights rese...

Page 623: ... con nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 5 Screw M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC063985 001 3 pcs xx1800002494 Continues on next page Product manual IRB 1100 623 3HAC064992 001 Revision L Copyright 2019 2022 ABB All right...

Page 624: ...ew to the hole 8 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 9 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page 624 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8...

Page 625: ...ure the timing belt tension 11 New belt 180 229 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 12 Continues on next page Product manual IRB 1100 625 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 gearbox Continued ...

Page 626: ... the division point Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003029 Insert the female header of the connectors to the connector plate 2 Continues on next page 626 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 1 R...

Page 627: ...ncorrectly the cables can be damaged 4 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 5 Tightening torque 0 8 Nm xx1800002489 Refitting the swing covers Note Action For robots with protection type Clean Room 1 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 1100 627 3HAC064992 001 R...

Page 628: ...800003607 Concluding procedure Note Action For robots with protection type Clean Room 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robot...

Page 629: ... Gear unit with pulley axis 2 Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAB3772 143 O ring on circular spline side Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAB3772 182 O ring on flexible spline side Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAB3701 70 Axis 2 radial sealing Co...

Page 630: ...r axis 1 and 2 mo tors 9x4 3x1 Steel 3HAC063985 001 Washer Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 757 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool f...

Page 631: ...utine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibr...

Page 632: ...en disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 4 Removing the axis 2 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 ...

Page 633: ...r 4 xx1800002489 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 re move from the plate 5 Continues on next page Product manual IRB 1100 633 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 634: ... as a reference when reconnecting 6 xx1800002491 Snap loose and remove the female head of the connector from the connector plate 7 xx1800002492 Remove the swing cover 8 Continues on next page 634 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 635: ...lly lift out the motor CAUTION A cooling pad is attached to the motor which may stick to the casting Always use a plastic sheet with caution to remove the pad from the casting Pay attention not to scratch the casting or damage the pad CAUTION Be aware of the motor cabling The motor cannot be removed completely until the connector is disconnected as shown in following step 12 Continues on next page...

Page 636: ...ned off 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 123 2 xx1800003002 Remove the cable bracket 3 Continues on next page 636 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 ...

Page 637: ...support is sealed with sealant marked red in the figure Always remove swing support carefully Tip If the swing support is hard to loosen from the lower arm use a plastic hammer to knock on the swing support lightly CAUTION The support cannot be removed completely Make sure the hanging support will not wear or damage the cable harness 3 Separating the swing from the lower arm Note Action DANGER Mak...

Page 638: ...ate the swing from the lower arm Tip If the swing is hard to loosen from the housing use a plastic hammer to knock on the swing lightly 4 Removing the axis 2 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge whe...

Page 639: ...earbox screws 4 xx1800003082 Remove the screws 5 xx1800003083 Pull out the gearbox 6 Removing the cable block Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 639 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Cont...

Page 640: ... procedures to refit the axis 2 gearbox Refitting the cable block Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Screw M2 5x6 12 9 Lafre 2C2B FC6 9 2 pcs Refit the cable block to the axis 2 gearbox 2 Tightening torque 0 6 Nm xx1800003084 Continues on next page 640 Product manual IRB 1...

Page 641: ...ne side 3HAB3772 182 xx1900002195 For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 3351 4 Check the O rings Replace if damaged 2 O ring on circular spline side 3HAB3772 143 xx1900002194 Continues on next page Product manual IRB 1100 641 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 ge...

Page 642: ...the swing to the lower arm Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 642 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 643: ...joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1900002201 Check the radial sealing on the swing support 2 Axis 2 radial sealing assembly tool included in the radial sealing as sembly tool set 3HAC074609 001 Replace the radial sealing if damaged The swing support must be removed completely before the radial sealing can be removed See Replacing the s...

Page 644: ...ion 3351 4 Apply a string of the sealant Sikaflex 521FC to the joint of the swing support Smooth out the sealant string using a finger tip Use washing up on finger tips to get a smooth joint If necessary add extra sealant to get a full cover joint 4 Securing the upper cable package to the axis 2 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened...

Page 645: ... free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 1 and 2 mo tors 3HAC071020 001 xx1800003603 Check the cooling pad Replace if damaged as shown in the following step 3 Continues on next page Product manual IRB 1100 645 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights res...

Page 646: ... con nector xx1800003027 Orient the motor correctly and fit it into the swing Tip Bend the motor signal cable back towards the swing support 5 Screw M4x16 12 9 Lafre 2C2B FC6 9 3 pcs Refit the screws and washers Note Do not tighten the screws yet 6 Washer 3HAC063985 001 3 pcs xx1800002494 Continues on next page 646 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All right...

Page 647: ...ew to the hole 8 Initial referenced force for used belt 68 18 75 04 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 9 Initial referenced force for new belt 97 4 107 2 N xx1900000029 Continues on next page Product manual IRB 1100 647 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8...

Page 648: ...ure the timing belt tension 11 New belt 180 229 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 12 Continues on next page 648 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 gearbox Continued ...

Page 649: ... the division point Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800002491 Insert the female header of the connector to the connector plate 2 Continues on next page Product manual IRB 1100 649 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 2 Re...

Page 650: ...the cables can be damaged 4 Screw M3x8 12 9 Lafre 2C2B FC6 9 2 pcs Refit the connector plate 5 Tightening torque 0 8 Nm xx1800002489 Refitting the swing covers Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 650 Product manual IRB 1100 3HAC064992 001 Revision L C...

Page 651: ...800003607 Concluding procedure Note Action For robots with protection type Clean Room 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robot...

Page 652: ...y axis 3 3HAC073218 001 Labyrinth sealing ring Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAC061327 009 O ring on circular spline side Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAC061327 008 O ring on flexible spline side Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAB3701 57 Axi...

Page 653: ...ooling pad for axis 3 and 4 mo tors 9x4 3x1 Steel 3HAC063985 001 Washer Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 757 Standard toolkit Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for IRB 1100 to be fitted ...

Page 654: ...ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibrat...

Page 655: ...sembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 4 Disconnecting the axis 3 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint edge when disassembling p...

Page 656: ...plate as shown in following step 4 xx1800003005 Slide the connectors out of the connector plate and disconnect the connectors FB3 MP3 Tip Take photos of the connector and cable position before disconnecting them to have as a reference when reconnecting 5 xx1800003006 Remove the cable bracket 6 Continues on next page 656 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All ...

Page 657: ...moved completely Make sure the hanging support will not wear or damage the cable harness 3 Loosening the axis 3 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 p...

Page 658: ...rom its grooves on the motor and gearbox 6 Separating the lower arm from the housing Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 658 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 659: ...he lower arm from the housing Tip If the lower arm is hard to loosen from the hous ing use a plastic hammer to knock on the lower arm lightly 4 Removing the axis 3 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION For robots with protection type Clean Room Always cut the paint with a knife and grind the paint ed...

Page 660: ...eans the axes can fall down Make sure axes are well supported before remov ing gearboxes 3 Continues on next page 660 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 661: ...7 Remove the labyrinth sealing ring lightly and evenly 5 xx1800003284 Remove the screws 6 Pull out the gearbox 7 Continues on next page Product manual IRB 1100 661 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 662: ...Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 662 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 663: ...or robots with protection type Clean Room option 3351 4 Check the O rings Replace if damaged 2 O ring on circular spline side 3HAC061327 009 xx1900002196 Continues on next page Product manual IRB 1100 663 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 664: ...0 12 9 Lafre 2C2B FC6 9 12 pcs Secure with screws 4 Tightening torque 1 8 Nm xx1800003284 Continues on next page 664 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 665: ...the screws and secure the labyrinth sealing ring with the screws 7 Tightening torque 0 8 Nm xx1900001425 Refitting the lower arm to the housing Note Action For robots with protection type Clean Room 1 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 1100 665 3HAC064992 001 Revision L Copyright 2019 20...

Page 666: ...s that have been opened and wipe the parts free from particles with spirit on a lint free xx1900002202 Check the radial sealing on the lower arm support 2 Axis 3 radial sealing assembly tool included in the radial sealing as sembly tool set 3HAC074609 001 Replace the radial sealing if damaged The lower arm support must be removed com pletely before the radial sealing can be removed See Replacing t...

Page 667: ...rque 8 Nm xx1800003088 Route the cable package through the lower arm support 4 Securing the axis 3 motor Note Action For robots with protection type Clean Room 1 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 1100 667 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8...

Page 668: ...ntire screw to the hole 3 Initial referenced force for used belt 21 7 23 94 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 4 Initial referenced force for new belt 31 34 2 N Continues on next page 668 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 3 Repla...

Page 669: ...109 Hz Use a sonic tension meter to measure the timing belt tension 6 New belt 113 143 Hz for reference only If the timing belt tension does not meet the require ment loosen the motor screws and readjust 7 Continues on next page Product manual IRB 1100 669 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 gearbox Continued ...

Page 670: ...rs into the connector plate and reconnect the connectors FB3 MP3 Tip See the number markings on the connectors for help to find the corresponding connector 2 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 3 Continues on next page 670 Product manual IRB 1100 3HAC064992 001 Re...

Page 671: ...lean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1900002179 For robots with protection class IP67 option 3350 670 For robots with protection type Clean Room option 3351 4 Check the gaskets Replace if damaged 2 Apply grease to the cable package cover all moving area of the package 3 Continues on next page Product manual IRB 1100 671 3HAC06499...

Page 672: ... that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles with spirit on a lint free cloth Calibration is detailed in section Calibration on page 711 Recalibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 672 Product manual IRB 11...

Page 673: ...le harness basic Used with protection type Clean Room 3HAC075514 001 Lower cable harness basic Clean Room Used with protection classes IP40 and IP67 3HAC075522 001 Lower cable harness CP CS and air hose without Ethernet Used with protection type Clean Room 3HAC075515 001 Lower cable harness Clean Room CP CS and air hose without Ether net Used with protection classes IP40 and IP67 3HAC075523 001 Lo...

Page 674: ...tection type Clean Room Replace if damaged 3HAC061959 007 Gasket for housing cover Used with protection class IP67 and protection type Clean Room Replace if damaged 3HAC061959 009 Gasket for wrist cover Cooling pads are wear parts One cooling pad sheet includes 10 pieces of small pad Replace if damaged with one piece each time 3HAC071021 001 Cooling pad for axis 3 and 4 mo tors 7x3 2x1 5 Steel 3HA...

Page 675: ...tor axis 4 motor fitting tool Required consumables Note Article number Consumable Cable straps FM 222 3HAC029132 001 Grease Loctite 243 3HAB7116 1 Locking liquid 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 Not...

Page 676: ...alibrated 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 Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 xx1800003289 Jog the robot to the specified position Axi...

Page 677: ...ean 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 123 2 xx1800002944 Remove the screws and carefully open the cover CAUTION Be aware of the cabling that is attached to the cover The cover can not be removed completely until the connectors are disconnected as shown in fol...

Page 678: ...plies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page 678 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2...

Page 679: ...e turned off 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 123 2 Continues on next page Product manual IRB 1100 679 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 g...

Page 680: ...r hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page 680 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserv...

Page 681: ...e when disassembling parts of the robot See Cut the paint or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 xx1800002995 Loosen the screws and move the motor slightly to slacken the timing belt 4 Continues on next page Product manual IRB 1100 681 3HAC06...

Page 682: ...al power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page 682 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights...

Page 683: ...unit to access the cable package locking screw on the axis 4 gearbox and then loosen the locking screw 4 xx1800003001 Disconnecting the axis 4 motor connectors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 1100 683 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserve...

Page 684: ...ote Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Pull out the upper cable harness from the housing 3 C...

Page 685: ...aint or surface on the robot before replacing parts on page 123 2 CAUTION Removing motors will release axes This means the axes can fall down Make sure axes are well supported before remov ing motors 3 xx1800003094 Loosen the screws and move the motor slightly to slacken the timing belt 4 xx1800003095 Remove the screws and washers 5 Continues on next page Product manual IRB 1100 685 3HAC064992 001...

Page 686: ...g the pulley cover and axis 4 timing belt Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues ...

Page 687: ...NGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 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 123 2 Continues on next page Product manual IRB 1100 687 3HAC064992 001 ...

Page 688: ... 1100 4 0 475 Separate the wrist from the housing 4 xx1800003100 Valid for IRB 1100 4 0 58 Separate the extender unit and wrist from the housing 5 Removing the axis 4 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 688 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All...

Page 689: ...supported before remov ing gearboxes 3 xx1800003300 Remove the screws 4 xx1800003310 Pull out the gearbox 5 Refitting the gearbox Use these procedures to refit the axis 4 gearbox Refitting the axis 4 gearbox Note Action For robots with protection type Clean Room 1 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...

Page 690: ...r robots with protection type Clean Room option 3351 4 Check the O rings Replace if damaged 2 O ring on circular spline side 3HAC061327 009 xx1900002198 Continues on next page 690 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 691: ... other 3 Valid for IRB 1100 4 0 475 xx1800003313 Valid for IRB 1100 4 0 58 xx1800003312 Screw M3x30 12 9 Lafre 2C2B FC6 9 12 pcs Secure with screws 4 Tightening torque 1 8 Nm Continues on next page Product manual IRB 1100 691 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 692: ...rticles with spirit on a lint free xx1800003075 Valid for IRB 1100 4 0 475 Refit the the wrist to the housing 2 xx1800003100 Valid for IRB 1100 4 0 58 Refit the extender unit and wrist to the housing 3 Continues on next page 692 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 693: ...protection type Clean Room Tightening torque 1 8 Nm xx1900002191 Refitting the axis 4 timing belt and pulley cover Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003098 Install the timing belt to the gearbox pulley and verify that the belt runs correctly in the groove of the pul...

Page 694: ...wipe the parts free from particles with spirit on a lint free Check that all assembly surfaces are clean and without damages the motor is clean and undamaged 2 Cooling pad for axis 3 and 4 mo tors 3HAC071021 001 xx1800003605 Check the cooling pad Replace if damaged 3 Continues on next page 694 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 ...

Page 695: ... in regard to the encircled motor con nector xx1800003287 Orient the motor correctly and fit it into the hous ing Note Make sure the motor flange does not press on the timing belt 5 xx1800003617 Install the timing belt to the motor pulley 6 Continues on next page Product manual IRB 1100 695 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 ge...

Page 696: ... tool 8 Adjusting the axis 4 timing belt tension Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 696 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 697: ...ing to the eye bolt 4 Used belt 20 09 22 05 N Pull the dynamometer to make the tension falling in the allowed force range Note Pay attention to the force application direction 5 New belt 28 7 31 5 N Continues on next page Product manual IRB 1100 697 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 698: ...350 670 For robots with protection type Clean Room option 3351 4 Rubber sealing washer on housing 3HAC064147 001 Tightening torque 2 Nm Refitting the upper cable harness through the axis 4 gearbox Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free Continues on next page 698 Product manual...

Page 699: ...onnectors with the masking tape CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 2 xx1800003601 Securing the upper cable package to the axis 4 gearbox Note Action For robots with protection type Clean Room 1 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 1100 69...

Page 700: ... cable protection tube surface is com pletely parallel with the pulley cover at one side and with the flange at the other side 2 Surfaces to be paralleled are shown in the following figures xx1800003019 xx1800003020 Continues on next page 700 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 701: ...m Valid for IRB 1100 4 0 475 xx1800003031 Note If there is locking liquid residues on the screw or screw hole please clean it before refitting Remove residual locking liquid after refitting Valid for IRB 1100 4 0 58 xx1800003001 Continues on next page Product manual IRB 1100 701 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Contin...

Page 702: ...on extender unit 3HAC067995 001 Tightening torque 2 Nm xx1800003000 Reconnecting the axis 4 motor connectors Note Action For robots with protection type Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003618 Check the cabling status Make sure the cabling is in vertical state and is not twisted 2 Continues on next page 702 ...

Page 703: ...mbly surfaces are clean and without damages the motor is clean and undamaged 2 Motor orientation orient the motor according to the figure below in regard to the encircled motor con nector xx1800003023 Orient the motor correctly and fit it into the lower arm Tip Leave the connectors FB5 and FB6 accessible from the process hub and the connectors MP5 and MP6 accessible from wrist side 3 Continues on ...

Page 704: ... adjustment screw to the motor Note Do not insert the entire screw to the hole 6 Initial referenced force for used belt 8 96 9 8 N for reference only Use a handheld dynamometer hooking to the screw and pull the dynamometer to reach the ini tial referenced force 7 Initial referenced force for new belt 12 8 14 xx1900000026 Continues on next page 704 Product manual IRB 1100 3HAC064992 001 Revision L ...

Page 705: ...en the motor screws and readjust 10 xx1900000007 Remove the adjustment screw from the motor 11 Reconnecting the axis 6 motor connectors Note Action For robots with protection type Clean Room 1 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 1100 705 3HAC064992 001 Revision L Copyright 2019 2022 ABB A...

Page 706: ...pe Clean Room 1 Clean the joints that have been opened and wipe the parts free from particles with spirit on a lint free xx1800003025 Reconnect the connectors FB5 MP5 Tip See the number markings on the connectors for help to find the corresponding connector 2 Route and secure the cabling with cable straps CAUTION Correct cable routing is highly important If the cables are routed and secured incorr...

Page 707: ...0 For robots with protection type Clean Room option 3351 4 Check the gasket Replace if damaged 2 xx1800002945 Reconnect the air hoses in a cross pattern Tip See the number markings on the air hoses for help to find the corresponding air hoses The air hoses with the same number connect to the same Y shaped connector 3 Continues on next page Product manual IRB 1100 707 3HAC064992 001 Revision L Copy...

Page 708: ... tool 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 Screw M3x8 12 9 Lafre 2C2B FC6 9 4 pcs Refit the cover 7 Tightening torque 1 2 Nm xx1800002944 Continues on next page 708 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 ...

Page 709: ...kage 4 Screw M3x8 12 9 Lafre 2C2B FC6 9 Refit the covers Wrist covers Housing cover 5 Tightening torque 1 2 Nm xx2000002150 Concluding procedure Note Action For robots with protection type Clean Room 1 Clean and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 123 Note After all repair work wipe the Clean Room robot free from particles...

Page 710: ...sure all safety requirements are met when performing the first test run 3 710 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 gearbox Continued ...

Page 711: ...eneric term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine can later on be used to re calibrate the robot back to the same po...

Page 712: ...racy has the option information printed on its name plate To regain 100 Absolute accuracy perform ance the robot must be recalibrated for abso lute 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 1100 It is the recommended method in or...

Page 713: ...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 ...

Page 714: ...age 717 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 ...

Page 715: ... marks IRB 1100 1 2 5 6 4 3 xx1800002455 CAUTION To calibrate the axis 6 the notch on the wrist must be aligned with the marked pin hole on the tool flange Before installing a tool on the tool flange make sure a visible mark has been made to the tool at the corresponding position Product manual IRB 1100 715 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 6 Calibration 6 2 1 S...

Page 716: ...n 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 xx1800002456 716 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 6 Calibration 6 2 2 Calibration movement d...

Page 717: ...e revolution counter with the FlexPendant on page 720 When all axes are positioned update the revolution counter 3 Correct calibration position of axis 4 When jogging the manipulator to synchronization position it is extremely important to make sure that axis 4 is positioned correctly Axis 4 can be calibrated at the wrong turn resulting in an incorrect manipulator calibration Make sure axis 4 is p...

Page 718: ...towards right proceed to step 4 2 0 60 120 240 180 300 xx1800003318 Cable harness twisting towards left Jog the axis 4 anti clockwise with the operator facing the rear until the cable harness is in vertic al state 3 Continues on next page 718 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 6 Calibration 6 3 1 Updating revolution counters on OmniCore ro...

Page 719: ...xx1800003011 If the axis is rotated one or more turns from its calibration position before updating the revolution counter the correct calibration position will be lost due to non integer gear ratio At delivery the manipulator is in the correct position Do NOT rotate axis 4 at power up before the revolution counters are updated Continues on next page Product manual IRB 1100 719 3HAC064992 001 Revi...

Page 720: ...ibration options are displayed Tap Revolution Counters 6 In the Selection column select the axes for which revolution counters need to be up dated Note A warning is displayed prompting you to check the cable harness status before pro ceeding with the revolution counter update for axis 4 See Correct calibration position of axis 4 on page 717 7 Tap Update A dialog box is displayed warning that the u...

Page 721: ...ounting 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 se...

Page 722: ...alibration 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 t...

Page 723: ...an 0 degrees Axis must be put in position 0 degrees 0 Special requirement X 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 calibr...

Page 724: ...rticle number Equipment etc Delivered as a set of calibration tools Required if Axis Calibration is the valid calib ration method for the robot The tool box also includes a unique calibra tion pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 3HAC074119 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibra...

Page 725: ...0951 Outer diameter A 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 Outer diameter A Product manual IRB 1100 725 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserv...

Page 726: ...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 xx1800003320 Continues on next ...

Page 727: ...rotective plug included a sealing in the bushing Replace damaged parts with new Note Article number Spare part Replace if damaged or missing 3HAC059556 001 Protective plug for bushing Continues on next page Product manual IRB 1100 727 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 6 Calibration 6 4 3 Installation locations for the calibration tools Continued ...

Page 728: ...HAC059557 001 Protective plug for bushing Clean Room Replace if damaged or missing 3HAC061926 001 Calibration pin cover 6 mm 728 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 6 Calibration 6 4 3 Installation locations for the calibration tools Continued ...

Page 729: ...d with protection type Clean Room Replace if damaged or missing 3HAC059557 001 Protective plug for bushing Clean Room Replace if damaged or missing 3HAC061926 001 Calibration pin cover 6 mm 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 th...

Page 730: ... to calibration The calibration procedure is described in the FlexPendant while conducting it Note Action 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 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes wil...

Page 731: ...ant 5 Fitting of calibration tools The figures show the calibration tool in contact with the fixed pin on each axis The position of the complete robot shown for each axis is only an example In order for the axis to be able to be moved to calibration position or in order for getting proper access to the calibration bushing other axes might need to be jogged to positions different from 0 degrees Inf...

Page 732: ...ration is finished the RobotWare program needs to be started again Use this procedure to take required action Action Situation Press and hold the three position enabling device and press Play The three position enabling device on the FlexPendant has been released during robot movement Continues on next page 732 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights re...

Page 733: ...g 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 Note Action xx1900001421 Reinstall the protective cover on the fixed calibra tion pin on each axis directly after the axis has...

Page 734: ...ration 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...

Page 735: ...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 man...

Page 736: ...program twice Do not change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 715 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on one side of the base 736 Pro...

Page 737: ...ectly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action Tap Jog 1 From the Mechanical unit list select a mechanical unit 2 From the Motion mode section select an axis set that need to be jogged 3 For example to jog axis 2 select the axis set Axis 1 3 Follow the screen instruction on ...

Page 738: ...This page is intentionally left blank ...

Page 739: ...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 wit...

Page 740: ...ilities between hardware and software options and their configuration The robot recently had a software upgrade Check connections software versions The robot has recently been moved from one site to another an already working robot 740 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 7 Troubleshooting 7 1 Introduction to troubleshooting Continued ...

Page 741: ...AUTION Allow hot parts to cool down 1 If the oil spill is small this step is sufficient Wipe off the oil or grease see Cleaning the IRB 1100 on page 98 2 Monitor the robot over time to see if new oil or grease occurs Check the gearbox oil level 3 Robots performing certain ex tremely heavy duty work cycles may be fitted with vented oil plugs These are not fitted to normal duty robots but can be pur...

Page 742: ... 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 Information Action CAUTION Allow hot parts to cool down 1 Verify that the service is done according to the mainte...

Page 743: ...nding equipment Possible causes The symptom can be caused by Faulty brake Faulty power supply to the brake Recommended actions The following actions are recommended Information Action Determine which motor s causes the robot to collapse 1 See the circuit diagram Check the brake power supply to the col lapsing motor during the Motors OFF state 2 If found faulty the motor must be replaced as a compl...

Page 744: ...orque or external forces for the joint can also be too high Recommended actions The following actions are recommended Information Action CAUTION Allow hot parts to cool down 1 Verify that the values for payload and arm load are set correctly 2 Verify that the value for ambient temperature setting in the controller is consistent with the actual operating temperature environment 3 The ways could be ...

Page 745: ... 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 contro...

Page 746: ... materials in the product and their respective use throughout the product Dispose components properly according to local regulations to prevent health or environmental hazards Example application Material Base base adapter swing swing support lower arm lower arm support swing covers motors gearboxes SMB unit etc Aluminium Serial measurement board Batteries Lithium Cables motors Copper Serial measu...

Page 747: ...l 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 d...

Page 748: ...h 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 A used robot does not have the same performance as on delivery Springs brakes bearings and other parts might be worn or broken 748 Produc...

Page 749: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 1100 749 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 9 Reference information 9 1 Introduction ...

Page 750: ...ty standard for industrial environments IEC 61000 6 2 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments IEC 61000 6 4 Safety of machinery Safety related parts of control systems Part 1 General principles for design normative reference from ISO 10218 1 ISO 13849 1 2006 Protection of electronic devices from electrostatic phenomena General requ...

Page 751: ... 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 1100 751 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 9 Reference information 9 2 Applicable standards Continued ...

Page 752: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 752 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 9 Reference information 9 3 Unit conversion ...

Page 753: ...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 Geomet thickness Lubricant Dimension 3 5 μm Gleitmo 603 Geomet 500 M6 M20 any length except M20x60 3 5 μm Gleitmo 603 Geomet 72...

Page 754: ...ening torque for 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 Tightening torque for oil lubricated screws with allen head screws...

Page 755: ...h 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 Tightening torque Nm Class 12 9 lubricated i Tightening torque Nm Class 10 9 lubricated i Dimension 8 M5 14 M6 35 28 M8 70 55 M10 120 96 M12 300 235 M16 550 460 M20 950 790 M24 i Lubricated with Molycote 1000 Gleitmo 603 ...

Page 756: ...essory 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 Note Action CAUTION The arm weighs 25 kg All lifting accessories used must be sized accord ingly 756 Product manual IRB 1100 3HAC064992 001 Revision L Copyright 2019 2022 ABB A...

Page 757: ...red are the sum of the standard toolkit and any tools listed in the instruction Contents standard toolkit Rem Tool Qty Socket head cap 2 17 mm 1 Torque wrench 0 3 45 Nm 1 For securing robot to foundation Torque wrench 50 Nm 5 Nm 1 Ratchet head for torque wrench 1 2 1 Hex socket head cap no 2 5 socket 1 2 bit L 110 mm 1 Small screwdriver 1 T handle with ball head 1 Small cutting plier 1 Plastic mal...

Page 758: ... if Axis Calibration is the valid calibration method for the robot The tool box also includes a unique calibration pin for IRB 1100 to be fitted to the tool flange during calibration of axis 6 Sonic tension meter Used for measuring the timing belt tension Dynamometer Used for measuring the timing belt tension Radial sealing assembly tool set 3HAC074609 001 Used with protection class IP67 and prote...

Page 759: ...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 1100 759 3HAC064992 001 Revision L Copyright 2019 2022 ABB All rights reserved 10 Spare parts 10 1 Spare part lists and illustrations ...

Page 760: ...This page is intentionally left blank ...

Page 761: ...ion jogging to 737 scales 715 calibration scales 715 CalibWare 712 carbon dioxide extinguisher 29 cleaning 98 climbing on robot 31 Cold environments 90 connecting the robot and controller cabling 84 copper disposal 746 D damaged bearings 742 dimensions robot 74 direction of axes 716 E environmental information 746 equipment robot 74 ESD damage elimination 49 sensitive equipment 49 expected life 97...

Page 762: ...illed gearbox 741 P pedestal installed on pedestal 28 personnel requirements 18 plastic disposal 746 positive directions axes 716 PPE 18 product standards 750 protection classes 43 protection type 43 protective equipment 18 protective wear 18 R recycling 746 regional regulations 28 release brakes 34 replacements report 119 replacing base 230 battery pack 111 cable package lower 178 upper 126 exten...

Page 763: ...ing 68 swing replacing 282 symbols safety 19 synchronization position 717 sync marks 715 system integrator requirements 28 system parameter Gravity Alpha 69 Gravity Beta 68 T technical data robot 40 temperatures operation 42 storage 42 testing brakes 35 timing belts inspecting 104 torques on foundation 40 transportation 745 troubleshooting safety 36 turning radius 48 U upcycling 746 updating revol...

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Page 765: ......

Page 766: ...7 22 87 2000 ABB Engineering Shanghai Ltd Robotics Discrete Automation No 4528 Kangxin Highway PuDong New 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 abb com robotics 3HAC064992 001 Rev L en Copyright 2019 2022 ABB All rights reserved Specifications subject to change without notice ...

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