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5.9.2 Replacing the axis-2 gearbox

Space required nearby robot

This section describes how to replace the gearbox without needing to remove the
cable harness and DressPack cable package (if installed) from the robot.

The described procedure requires free space on the floor nearby the robot. There
should be enough space to place foam boards, pallets or similar protective material
nearby the robot.

If needed, run axis-1 into a position that gives the required space. The figure shows
an example.

DANGER

The base shall be fitted to the foundation when performing this procedure!

xx2000000441

Continues on next page

Product manual - IRB 5720

469

3HAC079195-001 Revision: A

© Copyright 2022 ABB. All rights reserved.

5 Repair

5.9.2 Replacing the axis-2 gearbox

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Summary of Contents for IRB 5720

Page 1: ...ROBOTICS Product manual IRB 5720 ...

Page 2: ...Trace back information Workspace 22A version a18 Checked in 2022 03 17 Skribenta version 5 5 019 ...

Page 3: ...Product manual IRB 5720 OmniCore Document ID 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ranty 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 obtaine...

Page 5: ...stability 56 3 3 On site installation 56 3 3 1 Brief installation procedure 57 3 3 2 Installing a base plate 64 3 3 3 Lifting the robot 64 3 3 3 1 Lifting the robot with fork lift 65 3 3 3 2 Lifting and rotating a suspended mounted manipulator 66 3 3 3 3 Lifting the robot with roundslings 71 3 3 4 Orienting and securing the robot 75 3 3 5 Manually releasing the brakes 77 3 3 6 Setting the system p...

Page 6: ...Introduction 188 5 2 General procedures 188 5 2 1 Performing a leak down test 189 5 2 2 Mounting instructions for bearings 191 5 2 3 Mounting instructions for sealings 194 5 2 4 Cut the paint or surface on the robot before replacing parts 195 5 3 Lifting procedures 195 5 3 1 Lifting down the manipulator from inverted to floor standing position 198 5 4 Axes 1 and 2 198 5 4 1 Replacing the axis 1 ca...

Page 7: ...the calibration tools 572 6 4 4 Axis Calibration Running the calibration procedure 576 6 4 5 Reference calibration 578 6 5 Verifying the calibration 579 6 6 Checking the synchronization position 581 7 Troubleshooting 581 7 1 Introduction to troubleshooting 583 7 2 Oil and grease stains on motors and gearboxes 584 7 3 Mechanical noise or dissonance 586 7 4 Manipulator collapses on power down 587 8 ...

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Page 9: ...it to the foundation to making it ready for operation maintenance work repair work decommissioning work Note It is the responsibility of the integrator to conduct a risk assessment of the final application It is the responsibility of the integrator to provide safety and user guides for the robot system Who should read this manual This manual is intended for installation personnel maintenance perso...

Page 10: ...073447 001 Product manual OmniCore V250XT 3HAC080367 001 Circuit diagram IRB 5710 IRB 5720 3HAC065041 001 Technical reference manual System parameters 3HAC050944 001 Operating manual Service Information System Tip All documents can be found via myABB Business Portal www abb com myABB Revisions Description Revision First edition A 10 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ...

Page 11: ...issioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Applicati...

Page 12: ...ucts The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 12 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved Product documentation Continued ...

Page 13: ...so include specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 15 Illustrations The product is illustrated with general figures that does not take painting or protection type in consideration Likewise certain work methods or general information that is valid for several product models can be illustrated with illustrations that show a differe...

Page 14: ...This page is intentionally left blank ...

Page 15: ...peration 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 suppl...

Page 16: ...fluence of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot The plant liable must make sure that the personnel is trained on the robot and on responding to emergency or abnormal situations Personal protective equipment Use personal protective equipment as stated in the instructions 16 Product manual IRB 5720 3HAC079195 001 Revis...

Page 17: ...ided 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 ...

Page 18: ...used to indicate where to find additional information or how to do an operation in an easier way TIP 18 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 19: ...scription 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 xx0900...

Page 20: ...000815 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 20 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 1 Safety 1 2 2 Safety sy...

Page 21: ...ip over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 5720 21 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 22: ... move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Moving robot xx1700000813 The robot can move unexpectedly when floor standing Always use transportation lock screw in floor standing position Continues on next page 22 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 23: ...0001242 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 5720 23 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 24: ...that 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 24 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Contin...

Page 25: ...cy stop The protective stops and emergency stops are described in the product manual for the controller For more information see Product manual IRB 5720 25 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 26: ...le 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...

Page 27: ...obot 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 c...

Page 28: ...ment of robot arm WARNING Hazards due to the use of brake release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment 28 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 1 Safety 1 5 Safety during operation...

Page 29: ...ns 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...

Page 30: ...e instructions Al ways use the type of oil specified for the product Mixing types of oil may cause severe damage to the gearbox Do not mix types of oil Run the robot before changing the gearbox oil if possible Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When ch...

Page 31: ...ting temperatures are listed in Operating conditions robot on page 39 See safety instructions for the batteries in Material product safety data sheet Battery pack 3HAC043118 001 Unexpected movement of robot arm WARNING Hazards due to the use of brake release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator moveme...

Page 32: ...quire 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 ...

Page 33: ... 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 ...

Page 34: ...ld 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 inform...

Page 35: ...ake 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 5720 35 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 1 Safety 1 8 Safety during decommissioning ...

Page 36: ...This page is intentionally left blank ...

Page 37: ...oes not include additional options tools and other equipment fitted on the robot Loads on foundation robot The illustration shows the directions of the robots stress forces The directions are valid for all floor mounted tilted and inverted robots Torquexy Forcez Forcexy Torquez xx2100002622 Continues on next page Product manual IRB 5720 37 3HAC079195 001 Revision A Copyright 2022 ABB All rights re...

Page 38: ... kN Force xy 11 9 14 2 kN 11 9 6 kN Force z 34 5 kNm 20 1 kNm Torque xy 10 9 kNm 5 kNm Torque z Inverted Max load emergency stop Endurance load in operation Force 18 4 kN 7 7 kN Force xy 12 13 5 kN 12 5 7 kN Force z 35 3 kNm 20 1 kNm Torque xy 10 9 kNm 5 kNm Torque z Tilted Max load emergency stop Endurance load in operation Force 20 1 kN 10 4 kN Force xy 11 5 14 1 kN 11 5 6 2 kN Force z 35 1 kNm ...

Page 39: ...asticity is added i e the stiffness of the pedestal where the robot is mounted The minimum resonance frequency should not be interpreted as the resonance frequency of the building floor etc For example if the equivalent mass of the floor is very high it will not affect robot movement even if the frequency is well below the stated frequency The robot should be mounted as rigid as possibly to the fl...

Page 40: ... available protection types of the robot with the corresponding protection class Protection class i Protection type IP67 Manipulator protection type Standard IP67 Manipulator protection type Foundry Plus 2 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 restri...

Page 41: ...6 This illustration shows the unrestricted working range of the robot 1147 1922 910 2600 1407 2950 xx2100002338 Continues on next page Product manual IRB 5720 41 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 2 Technical data 2 2 Working range ...

Page 42: ...ted with option 3317 1 910 2600 1147 1922 1407 2950 xx2100002580 Continues on next page 42 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 2 Technical data 2 2 Working range Continued ...

Page 43: ...ation shows the unrestricted working range of the robot 1480 2322 1085 3000 3350 1808 xx2100002343 Continues on next page Product manual IRB 5720 43 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 2 Technical data 2 2 Working range Continued ...

Page 44: ...ed with option 3317 1 1085 3000 1480 2322 1808 3350 xx2100002607 Continues on next page 44 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 2 Technical data 2 2 Working range Continued ...

Page 45: ...tration shows the unrestricted working range of the robot 1428 1922 910 2600 2950 1407 xx2100002342 Continues on next page Product manual IRB 5720 45 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 2 Technical data 2 2 Working range Continued ...

Page 46: ...erted with option 3317 1 910 1428 1922 2600 1407 2950 xx2100002618 Continues on next page 46 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 2 Technical data 2 2 Working range Continued ...

Page 47: ...ration shows the unrestricted working range of the robot 1790 2322 1085 3000 3350 1808 xx2100002339 Continues on next page Product manual IRB 5720 47 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 2 Technical data 2 2 Working range Continued ...

Page 48: ...rted with option 3317 1 1790 1085 2322 3000 1808 3350 xx2100002619 Continues on next page 48 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 2 Technical data 2 2 Working range Continued ...

Page 49: ... 5720 180 2 6 IRB 5720 155 2 6 LID R910 R 2 6 0 0 170 170 xx2100002341 Continues on next page Product manual IRB 5720 49 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 2 Technical data 2 2 Working range Continued ...

Page 50: ...rk ing range axis 1 option on page 95 75 145 Axis 2 180 70 IRB 5720 180 2 6 IRB 5720 125 3 0 Axis 3 160 70 IRB 5720 155 2 6 LID IRB 5720 90 3 0 LID 300 Axis 4 130 IRB 5720 180 2 6 IRB 5720 125 3 0 Axis 5 120 ii IRB 5720 155 2 6 LID IRB 5720 90 3 0 LID Continues on next page 50 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 2 Technical data 2 2 Working rang...

Page 51: ...B 5720 90 3 0 LID i Option Extended Working Range Axis 1 3324 1 Not valid for option Inverted 3317 1 Not valid with DressPack ii Maximum combined movements reduced Product manual IRB 5720 51 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 2 Technical data 2 2 Working range Continued ...

Page 52: ...ay destroy sensitive electronics Safe handling Use one of the following alternatives Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly Use an ESD protective floor mat The mat must be grounded through a current limiting resistor Use a dissipative table mat The mat should provide a controlled discharge of static voltages and must...

Page 53: ...licable national and regional standards and regulations Safety information Before any installation work is commenced all safety information must be observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page15 before performing any installati...

Page 54: ... lifting accessory used if required is suitable to handle the weight of the robot as specified in Weight robot on page 37 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 39 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 39 7 Before taking ...

Page 55: ...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 685 55 626 55 7 0 2 0 50 70 xx2100000477 WARNING The robot is likely to be mechanically unstable if not secured to the foundation Product manual IRB 5720 55 3HAC079195 001 Revision A Copyright 202...

Page 56: ...or the manipulator 2 See Lifting the robot on page 64 Lift and secure the manipulator to the plat form foundation 3 See Orienting and securing the ro bot on page 71 See Connect the manipulator to the controller 4 See Configure the safety settings 5 See How to start and run the robot is described in the product manual for the controller 6 Install required equipment if any 7 DANGER Make sure all saf...

Page 57: ...ening the robot base directly onto The base plate has a greater number of fastening points to the foundation and makes a larger footprint which reduces the load on each fastening point to reduce surface pressure on the foundation contact points which minimizes the risk of wearing down an uneven surface and thereby causing changes in the robot fastening tightening torque to be able to prepare the i...

Page 58: ... 2x 12H7 0 0 018 2 x 1 x 4 5 2 x 1 8 1 H 7 2 0 1 2 3 2 1 M 5 0 1 A B D A B 0 2 Common Zone E F G H xx1500000246 Description Pos Hole for guide pin cylindrical see Guide pins on page 60 A B Common tolerance zone accuracy all over the base plate from one contact surface to the other E F G H Continues on next page 58 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights rese...

Page 59: ... 0 0 0 7 0 0 1 8 D C L 2x R22 5 B 3 x R 1 3x 90 3 x 4 C C xx1500000247 Continues on next page Product manual IRB 5720 59 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 2 Installing a base plate Continued ...

Page 60: ...mbly of guide pins 800 B B B B A B A Description Pos Cylindrical guide pin x2 A M5 x 40 Tightening torque 6 Nm x2 B Continues on next page 60 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 2 Installing a base plate Continued ...

Page 61: ...s for leveling bolts in the base plate A A A B B B B xx1500000312 Orienting grooves 3 pcs A Levelling bolts attachment holes 4 pcs B Continues on next page Product manual IRB 5720 61 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 2 Installing a base plate Continued ...

Page 62: ...pins 2 pcs A Base plate guide sleeve holes The illustration below shows the guide sleeve holes in the base plate A xx0300000045 Continues on next page 62 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 2 Installing a base plate Continued ...

Page 63: ...nsion 5 Shown in figure Base plate orienting grooves and leveling bolts on page 61 Fit the base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm ...

Page 64: ...sed with the tool 3HAC058825 001 Fork lift accessory set Contains fork lift pockets and all required hardware for installation on robot base User instructions are enclosed with the tool 3HAC047054 003 Fork lift accessory set Required for rotating the robot to an inverted position Fork lift truck with rotator attach ment Required documents Document number Document 3HAC061161 001 Directions for use ...

Page 65: ...nstruction is specified in Special tools on page 597 Any additional equipment required is specified in the instruction for the lifting accessory Contact ABB for more information How to lift and turn the robot into position for tilted position Contact ABB for more information Illustration xx2100002608 Product manual IRB 5720 65 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Inst...

Page 66: ... page 64 Lifting and turning tool 3HAC073537 001 See Lifting and rotating a suspended mounted manipulator on page 65 The robot can also be lifted with roundslings as detailed in this section Illustration lifting position This figure shows the robot in its lifting and transportation position 685 55 626 55 7 0 2 0 50 70 xx2100000477 Continues on next page 66 Product manual IRB 5720 3HAC079195 001 Re...

Page 67: ... m Roundsling B 1 pcs 2 m or 2 5 m depending on robot variant ii Roundsling C 4 pcs Lifting eye M20 D i Fit the roundsling with slack They prevent the robot from rotating if there is a sudden stop during transport ii Fit the roundsling with slack They prevent the robot from rotating if there is a sudden stop during transport Continues on next page Product manual IRB 5720 67 3HAC079195 001 Revision...

Page 68: ...ndslings Note Action 685 55 626 55 7 0 2 0 50 70 xx2100000477 Make sure the robot is positioned in the recom mended position for transportation and lifting WARNING The robot is mechanically unstable if not se cured to the foundation 1 CAUTION The weight of the IRB 5720 robot is IRB 5720 180 2 6 990 kg Inverted 1 005 kg IRB 5720 125 3 0 985 kg Inverted 1 000 kg IRB 5720 155 2 6 LID 1 050 kg Inverte...

Page 69: ... 2 m or 2 5 m depending on robot variant i Roundsling A 4 pcs 2 5 m Roundsling B 1 pcs 2 m or 2 5 m depending on robot variant ii Roundsling C 4 pcs Lifting eye M20 D i Fit the roundsling with slack They prevent the robot from rotating if there is a sudden stop during transport ii Fit the roundsling with slack They prevent the robot from rotating if there is a sudden stop during transport Continue...

Page 70: ...s be present under the suspended load 5 Raise the overhead crane to lift the robot 6 70 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 3 3 Lifting the robot with roundslings Continued ...

Page 71: ...ubric ated 90 v 0 9 Screw tightening yield point utilization factor v according to VDI2230 0 3 mm Level surface requirements Securing a floor mounted robot Use this procedure to orient and secure the robot floor mounted Note Action Make sure the installation site for the robot con forms to the specifications in section Technical data on page 37 1 The hole configuration of the base is shown in the ...

Page 72: ...nto its mounting position 7 Screws M24 x 100 8 pcs quality 8 8 Fit the securing screws and washers in the attach ment holes of the base 8 Washers 4 mm flat washer Tightening torque Tighten the bolts in a crosswise pattern to ensure that the base is not distorted 9 550 Nm screws lubricated with Molykote 1000 600 725 Nm typical 650 Nm screws none or lightly lubricated Securing an inverted robot Use ...

Page 73: ...ng it into its mounting position 6 Suitable screws lightly lubricated M24 x 100 8 pcs 8 8 Fit the bolts and washers in the base attachment holes Note Lightly lubricate screws before assembly 7 Suitable washer 4 mm flat washer Screw tightening yield point utiliza tion factor v according to VDI2230 90 v 0 9 Tightening torque CAUTION If high stress on screws are suspected replace used screws with new...

Page 74: ... 45 H8 8x 53 8x 30 1 6 4 x 3 x 4 5 8 x 4 9 5 SECTION L L 0 12 0 3 A 0 3 B B 2 0 2 5 H 8 25 H8 3 0 SECTION K K 0 12 0 3 A 25 H8 0 033 0 2x R12 5 2 7 0 2 R400 DETAIL J 0 3 A C 0 4 A 2 7 2 0 3 0 SECTION I I C xx2100000788 74 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 4 Orienting and securing the robot Continued ...

Page 75: ...t is equipped with a brake release unit Note Action The internal brake release unit is equipped with buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes 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 76 1 Continues on next page Pr...

Page 76: ... the controller power must be supplied to connector R1 MP on the robot in order 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 xx0600002937 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...

Page 77: ...red correctly in the system parameters so that the robot system can control the movements in the best possible way An incorrect definition of the mounting angle will result in Overloading the mechanical structure Lower path performance and path accuracy Some functions will not work properly for example Load Identification and Collision detection Gravity Beta When the robot is mounted other than fl...

Page 78: ...41593 180 Inverted mounting Defining the system parameters in RobotWare The value of the system parameters that define the mounting angle must be redefined when changing the mounting angle of the robot The parameters belong to the type Robot in the topic Motion The system parameters are described in Technical reference manual System parameters The system parameters are configured in RobotStudio or...

Page 79: ...tops 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 manu...

Page 80: ... CAD models online IRB 5720 180 2 6 2156 1023 1120 1142 5 670 320 381 200 390 1616 5 180 C L Axis 5 C L Axis 3 C L Axis 2 C L Axis 1 724 388 296 xx2100000796 Continues on next page 80 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 8 Fitting equipment on the robot robot dimensions ...

Page 81: ...Axis 2 C L Axis 3 C L Axis 5 C L Axis 1 724 296 388 xx2100000797 Continues on next page Product manual IRB 5720 81 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 8 Fitting equipment on the robot robot dimensions Continued ...

Page 82: ...is 5 C L Axis 3 C L Axis 2 C L Axis 1 724 388 296 346 xx2100000798 Continues on next page 82 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 8 Fitting equipment on the robot robot dimensions Continued ...

Page 83: ...s 2 C L Axis 3 C L Axis 5 C L Axis 1 724 296 388 333 xx2100000799 Continues on next page Product manual IRB 5720 83 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 8 Fitting equipment on the robot robot dimensions Continued ...

Page 84: ... on the frame Description JH 100 kgm2 Permitted extra load on frame JH JH0 M4 x R2 Recommended position see the fol lowing figure where JH0 is the moment of inertia of the equipment R is the radius m from the center of axis 1 M4 is the total mass kg of the equipment including bracket and harness 250 kg R xx2100000824 Continues on next page 84 Product manual IRB 5720 3HAC079195 001 Revision A Copyr...

Page 85: ... of gravity in the axis 3 extension a A M1 M1 xx2100000822 Mass center A 200 300 A xx2100000823 Center of gravity in the axis 3 extension A Continues on next page Product manual IRB 5720 85 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 8 Fitting equipment on the robot robot dimensions Continued ...

Page 86: ...8 324 97 5 125 5 60 60 95 95 C L Axis 3 R117 52 5 52 5 4 x M 8 1 6 M12 18 A A C C L Axis 3 190 R441 R3 98 324 20 80 2x M8 12 100 40 C xx2100002378 Smallest circumscribed radius axis 3 R3 Smallest circumscribed radius axis 4 R4 Continues on next page 86 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 8 Fitting equipment o...

Page 87: ...1 6 M12 18 R101 5 E E G C L Axis 3 190 R441 R3 98 324 20 80 2x M8 12 79 5 G xx2100002379 Smallest circumscribed radius axis 3 R3 Smallest circumscribed radius axis 4 R4 Continues on next page Product manual IRB 5720 87 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 8 Fitting equipment on the robot robot dimensions Continued ...

Page 88: ...Axis 1 388 2x M8 xx2100002380 Allowed positions for attachment holes 4x M12 through Avoid damaging cables when drilling A Continues on next page 88 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 8 Fitting equipment on the robot robot dimensions Continued ...

Page 89: ...2x M6 14 10 2 H7 15 30 15 154 154 40 138 170 138 170 78 105 100 100 8 28 3x M6 14 20 4x M6 14 xx2100000812 Continues on next page Product manual IRB 5720 89 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 8 Fitting equipment on the robot robot dimensions Continued ...

Page 90: ...80 H7 1 X 45 0 3 F D E 0 07 F D D E F xx2100000807 IRB 5720 155 2 6 LID IRB 5720 90 3 0 LID 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 90 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 3 8 Fitti...

Page 91: ...e working range values set in the software parameters Note The mechanical stops are only installed as safety precaution to physically stop the robot from exceeding the working range set A collision with a mechanical stop always requires actions for repair and troubleshooting Movable mechanical stopii Fixed mechanical stopi Axis yes The working range can be reduced by altering the parameter values ...

Page 92: ...duction of working range Graduation of limited working range from 5 and 125 in both directions 15 Illustration reduced working range 5 5 5 0 5 0 125 125 A A xx2100000973 WARNING If the mechanical stop pin is deformed after a hard collision it must be replaced Deformed movable stops and or additional stops as well as deformed attachment screws must also be replaced after a hard collision Continues ...

Page 93: ... listed in the table can be out of date See the latest spare parts of the IRB 5720 via myABB Business Portal www abb com myABB Note Article number Spare part Screws and washers are en closed 3HAC048533 003 Movable mechanical stop set axis 1 Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 596 Standard toolkit Continues on next page P...

Page 94: ...nical stop according to the figure Location of the mechanical stops on page 93 Note Install the washer with the chamfer turned downwards A A xx2100000974 3 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Adjust the software working range limitations system parameter configuration to corres pond to the ...

Page 95: ...ple a label If the robot is delivered with the option Extended work range then such a label is included on delivery Extending the working range Note Illustration Action Configure the safety setup and verify it by test 1 xx2100001410 Hold the mechanical stop pin in a firm grip and remove it by unscrewing the attach ment screw 2 With the option Extended working range the maximum value for the system...

Page 96: ...ve see Application manual Functional safety and SafeMove 96 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 4 3 Extended working range axis 1 option Continued ...

Page 97: ...th equipment 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 See the product manual for the controller see document number in References on page 10 Robot cables These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Conn...

Page 98: ...540 1 Signal cable shielded 22 m 3HAC2566 1 Signal cable shielded 30 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 98 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 5 1 Robot cabli...

Page 99: ...rounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx2100000853 Product manual IRB 5720 99 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 3 Installation and commissioning 3 5 1 Robot cabling and connection points Continued ...

Page 100: ...ict 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 operat...

Page 101: ... in different sections and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 15 before performing any service ...

Page 102: ...pecified in months regardless of whether the system is running or not Operating time specified in operating hours More frequent running means more frequent maintenance activities Robots with the functionality Service Information System activated can show active counters in the device browser in RobotStudio or on the FlexPendant 102 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 A...

Page 103: ...111 x Inspecting the dampers Inspecting the information labels on page 108 x Inspecting the information labels Inspecting the axis 1 mechanical stop on page 113 x Inspecting the mechanical stop Inspect the oil level in the actual gearbox if there is a suspected leakage after an oil change or a maintenance or repair activity where draining and filling oil is required Inspecting the oil level in gea...

Page 104: ...oil in axis 6 gearbox Replacing the SMB battery on page 180 x iii Replacing the SMB battery pack i Operating hours counted by the DTC Duty Time Counter ii Replace when damage or cracks is detected or life limit is approaching that specified in section Expected component life on page 105 iii The battery is to be replaced at given maintenance interval or at battery low alert 104 Product manual IRB 5...

Page 105: ...stem 40 000 hours Gearboxes i Examples of 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 movem...

Page 106: ...xis 1 motor as an example xx1500001057 Plug in the evacuation hole Robots with protection type Standard have a protection filter installed in the evacuation hole Robots with protection type Foundry Plus have a transparent plug sight glass installed in the evacuation holes xx1800000102 xx1800000101 Transparent plug Foundry Plus Protection filter Standard Continues on next page 106 Product manual IR...

Page 107: ... or grease on page29 2 xx1500001057 Do a leakage check of the sight glass evacuation hole of each motor If any oil is available on the sight glass or if any oil has been spilled out from the evacuation hole replacement of the motor is recommended 3 Replacing of motors is described in the repair chapter Motors on page 319 Product manual IRB 5720 107 3HAC079195 001 Revision A Copyright 2022 ABB All ...

Page 108: ...tal www abb com myABB The figures show the location of the information labels to be inspected The symbols are described in section Safety symbols on manipulator labels on page 19 110 kg 90 kg 180 kg A A A A B E D L M J K xx2100002292 Continues on next page 108 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 2 Inspecting the information lab...

Page 109: ...bel Mobilgear 600 XP 320 3HAC021485 001 A Lubrication label Kyodo Yushi TMO 150 3HAC032726 001 B Lubrication label 3HAC032905 001 C Continues on next page Product manual IRB 5720 109 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 2 Inspecting the information labels Continued ...

Page 110: ...14257 1 M Warning label Extended working range 3HAC021761 001 N Required tools and equipment Visual inspection no tools are required Inspecting labels Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate se...

Page 111: ...pers B Axis 5 dampers C Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 5720 via myABB Business Portal www abb com myABB Continues on next page Product manual IRB 5720 111 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 3 Inspecting the dampers ...

Page 112: ...ng the safeguarded space 1 Check all dampers for damage cracks or exist ing impressions larger than 1 mm 2 Check attachment screws for deformation 3 Attachment screws If any damage is detected the damper must be replaced with a new one 4 Axis 2 and axis 3 M6x60 8 8 A2F 9ADA624 65 Axis 5 M6x25 Steel 8 8 A2F 9ADA624 58 Locking liquid Loctite 2400 3HAC041807 004 DANGER Make sure all safety requiremen...

Page 113: ...ANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 Inspect the axis 1 mechanical stop pin 2 If the mechanical stop pin is bent or damaged it must be replaced Note The expected life of gearboxes can be reduced after collision with the mechanical stop Continues on next page Product manual IRB 5720 113 3HAC079195...

Page 114: ...rtighten the attachment screw use specified tightening torque 3 Locking liquid 3HAC041807 004 Loctite 2400 The attachment screw is accessed from the side xx2100001410 114 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 4 Inspecting the axis 1 mechanical stop Continued ...

Page 115: ...the cable harness Use this procedure to inspect cable harness of axes 1 6 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 Continues on next page Product manual IRB 5720 115 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 5 Inspecting the cable harness ...

Page 116: ...otor cables visually for any damage 4 Check the connectors at the base visually for any damage 5 xx2100001473 Check the cabling going through the protec tion tube to detect possible cable chafing by using your hands inside the tube to feel the cables Ensure that the cables are un damaged Remove any objects that may cause pos sible cable chafing Replace damaged cabling if any 6 See Removing the cab...

Page 117: ...r standing and measure the oil level according to floor standing manipulator xx2100002062 Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 596 Standard toolkit Used to inspect the oil level in the axis 1 gearbox when the manipulator is mounted inverted The tool also includes an air vent 3HAC061881 001 Oil level gauge Continues on nex...

Page 118: ...his procedure to inspect the oil level in the gearbox when the robot is floor standing Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 2 Make sure that the oil temperature is 25 C 10 C 3 ...

Page 119: ...tion about how to drain or fill with oil is found in section Changing the oil in axis 1 gearbox on page 143 O ring 3HACxxx Refit the oil plug with a new o ring 7 Tightening torque 24 Nm xx2100002056 DANGER Make sure all safety requirements are met when performing the first test run 8 Continues on next page Product manual IRB 5720 119 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved...

Page 120: ...arbox lubricants oil or grease on page 29 2 Make sure that the oil temperature is 25 C 10 C CAUTION The gearbox can contain an excess pres sure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 3 Oil level gauge 3HAC061881 001 xx1700000349 Remove the protective cap and install the ventilating valve enclosed with the oil level gauge 4 Continues on next page 1...

Page 121: ... oil level is at level measurement mark 57 on tool 5 mm 7 A Valve in open position B Level measurement marks Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 8 Further information about how to drain or fill with oil is found in section Changing the oil in axis 1 gearbox on page 143 Continues on next page Product manual IRB...

Page 122: ...ps 9 DANGER Make sure all safety requirements are met when performing the first test run 10 122 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 6 Inspecting the oil level in axis 1 gearbox Continued ...

Page 123: ...Note Article number Equipment Content is defined in section Standard toolkit on page 596 Standard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 141 Lubricating oil Continues on next page Product manual IRB 5720 123 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 7 Inspecting the oil level in...

Page 124: ...e gearbox Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 2 Make sure that the oil temperature is 25 C 10 C 3 Continues on next page 124 Product manual IRB 5720 3HAC079195 001 Revision A C...

Page 125: ...Type of oil and total amount is detailed in Technical reference manual Lubric ation in gearboxes Add or drain oil if required 6 Further information about how to drain or fill with oil is found in section Chan ging the oil in axis 2 gearbox on page 154 Continues on next page Product manual IRB 5720 125 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 7 Inspecting t...

Page 126: ...00002059 Option Inverted 3317 1 xx2100002061 DANGER Make sure all safety requirements are met when performing the first test run 8 126 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 7 Inspecting the oil level in axis 2 gearbox Continued ...

Page 127: ...dard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 141 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HACxxx O ring Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 5720 127 3HAC079195 001 Rev...

Page 128: ...is 2 0 Axis 3 170 Axis 4 no significance Axis 5 no significance Axis 6 no significance 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 Make sure that the oil temperature is 25 C 10 C 4 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 5 Continues ...

Page 129: ...tion 170 to 175 0 10 mm 7 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 8 Further information about how to drain or fill with oil is found in section Changing the oil in axis 3 gearbox on page 160 O ring 3HACxxx Refit the oil plug with a new o ring 9 Tightening torque 24 Nm xx2100002064 Continues on next page Product ma...

Page 130: ...l safety requirements are met when performing the first test run 10 130 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 8 Inspecting the oil level in axis 3 gearbox Continued ...

Page 131: ...dard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 141 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HACxxx O ring Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 5720 131 3HAC079195 001 Rev...

Page 132: ...c power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 Make sure that the oil temperature is 25 C 10 C 4 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 5 xx2100002072 Open the oil plug 6 Check the oil level 7 Required oil level is 0 10 mm below oil plug hole Continues on next pag...

Page 133: ...d in section Changing the oil in axis 4 gearbox on page 165 O ring 3HACxxx Refit the oil plug with a new o ring 9 Tightening torque 24 Nm xx2100002072 DANGER Make sure all safety requirements are met when performing the first test run 10 Product manual IRB 5720 133 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 9 Inspecting the oil level in axis 4 gearbox Contin...

Page 134: ...dard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 141 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HACxxx O ring Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page 134 Product manual IRB 5720 3HAC079195 001 Rev...

Page 135: ...Axis 6 no significance 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 Make sure that the oil temperature is 25 C 10 C 4 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 5 Continues on next page Product manual IRB 5720 135 3HAC079195 001 Revision...

Page 136: ...ormation about how to drain or fill with oil is found in section Changing the oil in axis 5 gearbox on page 170 O ring 3HACxxx Refit the oil plug with a new o ring 9 Tightening torque 24 Nm xx2100002075 DANGER Make sure all safety requirements are met when performing the first test run 10 136 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3...

Page 137: ...dard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 141 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HACxxx O ring Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 5720 137 3HAC079195 001 Rev...

Page 138: ...ion Axis 1 no significance Axis 2 0 Axis 3 0 Axis 4 180 Axis 5 0 Axis 6 no significance 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 Make sure that the oil temperature is 25 C 10 C 4 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 5 Continues...

Page 139: ...is oil is visible through the oil plug hole If the oil level is not visible rotate axis 5 up to additionally 5 to achieve visual check of oil level 8 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 9 Further information about how to drain or fill with oil is found in section Changing the oil in axis 6 gearbox on page 175 ...

Page 140: ...torque 20 Nm xx2100002077 DANGER Make sure all safety requirements are met when performing the first test run 11 140 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 3 11 Inspecting the oil level in axis 6 gearbox Continued ...

Page 141: ...of lubrication article number as well as the amount in the specific gearbox can be found in Technical reference manual Lubrication in gearboxes available for registered users on myABB Business Portal www abb com myABB Location of gearboxes The figure shows the location of the gearboxes xx2100002078 Axis 1 gearbox A Axis 2 gearbox B Axis 3 gearbox C Axis 4 gearbox D Axis 5 gearbox E Axis 6 gearbox ...

Page 142: ...eumatic Nipple for quick connect fitting with o ring Used to inspect the oil level in the axis 1 gear box when the manipulator is mounted inverted Oil level gauge The tool also includes an air vent 142 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 4 1 Type of lubrication in gearboxes Continued ...

Page 143: ...enting and inspection B Option Inverted 3317 1 xx2100001475 Oil nipple for draining and filling with an oil dispenser A Oil nipple for venting B Changing oil in an inverted robot The oil in the axis 1 gearbox can either be changed when the robot is inverted or standing on the floor Continues on next page Product manual IRB 5720 143 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4...

Page 144: ...g oil plug 3HACxxx O ring Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearboxes Floor mounted robot Draining the axis 1 gearbox Use this procedure to drain the gearbox Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 WARNING Ha...

Page 145: ...00001476 Remove the protective cap from the nipple of the oil hole and connect the oil dis penser 6 Suck out the oil with the oil dispenser Note There will be some oil left in the gear after draining 7 WARNING Used oil is hazardous material and must be disposed of in a safe way See Decom missioning on page 587 for more informa tion 8 Continues on next page Product manual IRB 5720 145 3HAC079195 00...

Page 146: ...p from the nipple of the oil hole and connect the oil dis penser 3 xx2100001477 Remove the plug from the venting hole Note The venting hole is opened to let out air during the filling process 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil with the oil dis penser Note The amount of oil to be filled depends on the amount ...

Page 147: ...e nipple 7 O ring 3HACxxx Refit the oil plug with a new o ring 8 Tightening torque 24 Nm xx2100001477 Note After all repair and maintenance work in volving oil always wipe the robot clean from all surplus oil The robot color can otherwise be discolored 9 DANGER Make sure all safety requirements are met when performing the first test run 10 Continues on next page Product manual IRB 5720 147 3HAC079...

Page 148: ...ure that the oil temperature is 25 C 10 C 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 4 Oil level gauge 3HAC061881 001 xx1700000349 Remove the protective cap and install the ventil ating valve enclosed with the oil level gauge 5 Continues on next page 148 Product manual IRB 5720 3HAC079195 001 Rev...

Page 149: ...ut as much remaining oil as possible with a small hose or syringe through the venting hole 10 WARNING Used oil is hazardous material and must be dis posed of in a safe way See Decommissioning on page 587 for more information 11 Note After all repair and maintenance work involving oil always wipe the robot clean from all surplus oil The robot color can otherwise be discolored 12 Continues on next p...

Page 150: ... the safe guarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 2 Oil level gauge 3HAC061881 001 xx1700000349 Remove the protective cap and install the ventilating valve enclosed with the oil level gauge Note The venting hole is opened to let out air during the filling process 3 Continues on next page 150 Product manual IRB 5720 ...

Page 151: ...uge 6 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil with the oil dis penser Note The amount of oil to be filled depends on the amount previously being drained 7 Remove the oil dispenser 8 Continues on next page Product manual IRB 5720 151 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 4 ...

Page 152: ...ve the oil level gauge 10 Remove the ventilating valve from the up per oil nipple 11 Turn on the power to the robot and let axis 1 move for approximately 5 minutes Tip This is done to eliminate any air bubbles in the oil 12 Let the manipulator stand still 1 hour 13 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded ...

Page 153: ... 5 cl Drain or fill more oil if required 18 A Valve in open position B Level measurement marks Remove the oil dispenser and the oil level gauge 19 Refit the protective cap to the nipple Remove the ventilating valve from the up per oil nipple 20 Refit the protective cap to the nipple Note After all repair and maintenance work in volving oil always wipe the robot clean from all surplus oil The robot...

Page 154: ...ling with an oil dispenser A Oil plug hole for ventilation and inspection B Option Inverted 3317 1 xx2100002088 Oil plug with nipple for draining and filling with an oil dispenser A Oil plug hole for ventilation and inspection B Continues on next page 154 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 4 3 Changing the oil in axis 2 gearbox ...

Page 155: ...uments Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearboxes Draining the axis 2 gearbox Use this procedure to drain the gearbox Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearb...

Page 156: ...059 Remove the plug from the ventilation hole WARNING Open the venting hole while using the dis penser to avoid damaging vital parts in the gear 5 Option Inverted 3317 1 xx2100002061 Continues on next page 156 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 4 3 Changing the oil in axis 2 gearbox Continued ...

Page 157: ...this procedure to refill the gearbox with oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 2 Continues on next page Product manual IRB 5720 157 3HAC079195 001 Revision A Copyright 2022...

Page 158: ...059 Remove the plug from the ventilation hole WARNING Open the venting hole while using the dis penser to avoid damaging vital parts in the gear 4 Option Inverted 3317 1 xx2100002061 Continues on next page 158 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 4 3 Changing the oil in axis 2 gearbox Continued ...

Page 159: ...e oil stops sinking before measuring the oil level 6 Required oil level is 0 10 mm below oil plug hole inverted robot More information is found in Inspecting the oil level in axis 2 gearbox on page 124 Remove the oil dispenser 7 Refit the protective cap on the nipple O ring 3HACxxx Refit the oil plug with a new o ring 8 Tightening torque 24 Nm xx2100002059 Option Inverted 3317 1 xx2100002061 DANGE...

Page 160: ...enser can be found in section Type of lubric ation in gearboxes on page 141 Oil dispenser Content is defined in section Standard toolkit on page 596 Standard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 141 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HACxxx O ring Required documents Note Document...

Page 161: ...ce Axis 6 no significance 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 4 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let t...

Page 162: ...Floor mounted robot Run axis 3 to 0 while draining to reach all oil Option Inverted 3317 1 Run axis 3 to 180 while draining to reach all oil Note There will be some oil left in the gear after draining WARNING Used oil is hazardous material and must be disposed of in a safe way See Decom missioning on page 587 for more informa tion 9 Continues on next page 162 Product manual IRB 5720 3HAC079195 001...

Page 163: ...ipple of the oil hole and connect the oil dis penser 3 xx2100002064 Remove the plug from the ventilation hole WARNING Open the venting hole while using the dis penser to avoid damaging vital parts in the gear 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previou...

Page 164: ... stops sinking before measuring the oil level 6 Remove the oil dispenser 7 Refit the protective cap on the nipple O ring 3HACxxx Refit the oil plug with a new o ring 8 Tightening torque 24 Nm xx2100002064 DANGER Make sure all safety requirements are met when performing the first test run 9 164 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 ...

Page 165: ...on Type of lubric ation in gearboxes on page 141 Oil dispenser Content is defined in section Standard toolkit on page 596 Standard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 141 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HACxxx O ring Required documents Note Document number Document name 3HAC0...

Page 166: ...supply to the robot before entering the safe guarded space 3 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 4 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 5 Place the oil collecting vessel underneath the oil drain plug 6 Continues on next pa...

Page 167: ...NING Used oil is hazardous material and must be disposed of in a safe way See Decom missioning on page 587 for more informa tion 9 O ring 3HACxxx Refit the oil plug for the drainage hole with a new o ring 10 Tightening torque 24 Nm xx2100002095 Continues on next page Product manual IRB 5720 167 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 4 5 Changing the oil in...

Page 168: ...iled in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previously being drained 4 Required oil level is 0 10 mm below oil plug hole Inspect the oil level CAUTION The oil level sinks when the oil fills all cav ities in the gearbox Wait until the oil stops sinking before measuring the oil level 5 See Inspectin...

Page 169: ...ning torque 24 Nm xx2100002072 DANGER Make sure all safety requirements are met when performing the first test run 7 Product manual IRB 5720 169 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 4 5 Changing the oil in axis 4 gearbox Continued ...

Page 170: ...Required tools and equipment Note Article number Equipment The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubric ation in gearboxes on page 141 Oil dispenser Content is defined in section Standard toolkit on page 596 Standard toolkit Continues on next page 170 Product manual IRB 572...

Page 171: ...s 2 0 Axis 3 0 Axis 4 180 Axis 5 no significance Axis 6 no significance 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 4 CAUTION The gearbox can contain an excess of pressure that can be hazardous...

Page 172: ...G Used oil is hazardous material and must be disposed of in a safe way See Decom missioning on page 587 for more informa tion 9 O ring 3HACxxx Refit the oil plug for the drainage hole with a new o ring 10 Tightening torque 24 Nm xx2100002099 Continues on next page 172 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 4 6 Changing the oil in ax...

Page 173: ...ual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previously being drained 4 Required oil level is 0 10 mm below oil plug hole Inspect the oil level at the oil fill level hole level plug CAUTION The oil level sinks when the oil fills all cav ities in the gearbox Wait until the oil stops sinking before measuring the oil level 5 More i...

Page 174: ...ning torque 24 Nm xx2100002075 DANGER Make sure all safety requirements are met when performing the first test run 7 174 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 4 6 Changing the oil in axis 5 gearbox Continued ...

Page 175: ...on Type of lubric ation in gearboxes on page 141 Oil dispenser Content is defined in section Standard toolkit on page 596 Standard toolkit Required consumables and wear parts Note Article number Wear part See Type of lubrication in gearboxes on page 141 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HACxxx O ring Required documents Note Document number Document name 3HAC0...

Page 176: ...robot before entering the safe guarded space 3 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 29 4 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 5 Place the oil collecting vessel underneath the oil drain plug 6 Continues on next page 176 Product...

Page 177: ...G Used oil is hazardous material and must be disposed of in a safe way See Decom missioning on page 587 for more informa tion 9 O ring 3HACxxx Refit the oil plug for the drainage hole with a new o ring 10 Tightening torque 20 Nm xx2100002101 Continues on next page Product manual IRB 5720 177 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 4 7 Changing the oil in ax...

Page 178: ...nd total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previously being drained 4 See Inspecting the oil level in axis 6 gear box on page 138 Check the oil level CAUTION The oil level sinks when the oil fills all cav ities in the gearbox Wait until the oil stops sinking before measurin...

Page 179: ...ning torque 20 Nm xx2100002077 DANGER Make sure all safety requirements are met when performing the first test run 7 Product manual IRB 5720 179 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 4 7 Changing the oil in axis 6 gearbox Continued ...

Page 180: ...Only replace with the specified spare part or an ABB approved equivalent 3HAC044075 001 Battery pack Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 596 Standard toolkit Removing the battery Use this procedure to remove the SMB battery Note Action This is done in order to facilitate updating of the revolution counter Jog the robot t...

Page 181: ... can cause shortage on the boards which can result in hazardous failures 4 Pull out the battery and disconnect the battery cable 5 Remove the SMB battery Note Battery includes protection circuits Only replace with a specified spare part or with an ABB ap proved equivalent 6 Refitting the battery Use this procedure to refit the SMB battery Note Action DANGER Turn off all electric power supply hydra...

Page 182: ...cess Note Make sure that the connector is assembled in the correct direction according to its keying 3 Tightening torque 6 Nm xx2100002131 Secure the SMB battery cover with its attachment screws 4 See Updating revolution counters on page 563 Update the revolution counters 5 DANGER Make sure all safety requirements are met when performing the first test run 6 182 Product manual IRB 5720 3HAC079195 ...

Page 183: ...mple 6 months 3 If the oil level is decreased replace the gearbox 4 Oil spills discolors painted surfaces Oil spills on painted surfaces of the robot can result in discoloration Note After all repair and maintenance work involving oil always wipe the robot clean from all surplus oil WARNING Turn off all electrical power supplies to the robot before starting the cleaning Special cleaning considerat...

Page 184: ... and steam on page 184 Cleaning with water and steam Instructions for rinsing with water ABB robots with protection types Standard Foundry Plus Wash or Foundry Prime can be cleaned by rinsing with water water cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encap...

Page 185: ...cable movement Clean the cables if they have a crusty surface for example from dry release agents Cassette sealings Minor seepage of grease from the seals can occur Wipe down affected areas with a dry cloth Product manual IRB 5720 185 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 4 Maintenance 4 5 1 Cleaning the IRB 5720 Continued ...

Page 186: ...This page is intentionally left blank ...

Page 187: ...by ABB Report replaced units Note When replacing a part on the IRB 5720 report to your local ABB the serial number the article number and the revision of both the replaced unit and the replacement unit This is particularly important for safety equipment to maintain the safety integrity of the installation Safety information Make sure to read through the chapter Safety on page 15 before commencing ...

Page 188: ...N The pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that...

Page 189: ...be exposed to any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradual...

Page 190: ... started During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 190 Product manual IR...

Page 191: ... 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 or damage are found the shaft must be replaced since it may result in future leakage Do not try to grind or polish the shaft surface to get rid of the defect 2 Article number is specified in Equipment on page 191 A B C xx2000000071 ...

Page 192: ...used because leakage could occur Clean the surfaces properly in accordance with the recommendations of ABB 2 Distribute the sealing compound evenly over the surface preferably with a brush 3 Tighten the screws evenly when fastening 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 da...

Page 193: ... contamination Lubricate the o ring with grease 4 Tighten the screws evenly while assembling 5 Check that the o ring is not squashed outside the o ring groove 6 Product manual IRB 5720 193 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 2 3 Mounting instructions for sealings Continued ...

Page 194: ...e White 3HAC067974 001 Touch up paint Standard Foundry Plus 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 2 194 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights re...

Page 195: ...ment Required documents Document number Document 3HAC061161 001 Directions for use Fork lift accessory for IRB 5710 IRB5720 TBD xxx new document required written by UserDoc xxx Directions for use Fork lift accessory for IRB 5710 IRB5720 Removing the robot from inverted position Use these procedures to lift down the robot from inverted position and rotate it to floor standing Lifting down the robot...

Page 196: ... 5720 125 3 0 985 kg Inverted 1 000 kg IRB 5720 155 2 6 LID 1 050 kg Inverted 1 070 kg IRB 5720 90 3 0 LID 1 050 kg Inverted 1 060 kg All lifting accessories used must be sized accord ingly 6 See user instructions enclosed with the fork lift accessory set Install the fork lift pockets to the robot DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instruct...

Page 197: ...truc tions DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user in structions for the tool Lifting and turning tool 3HAC073537 001 Quantity 8 pcs xx1600002098 Remove the bolts that secure the robot to the foundation 9 Follow the user instructions en closed with the turning tool Rotate the robot to floor standing position 10 Attachment screws M24 x 100 min 4 ...

Page 198: ...able harness from the base 2 Remove the sealing ring and protection tube from the frame 3 Replace the cassette sealing Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 5720 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC070194 013 Cassette sealing Continues on next page 19...

Page 199: ...pment For removing and fitting cassette sealing on axis 1 3HAC079880 001 Replacement tool for cassette sealing Content is defined in section Standard toolkit on page 596 Standard toolkit Removing the cassette sealing Use these procedures to remove the cassette sealing Preparations before removing the cassette sealing Note Action Jog the robot to synchronization position 1 DANGER Turn off all elect...

Page 200: ...Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx2100000981 Remove the base cover 2 xx2100001109 Loosen the connectors R1 MP R1 SMB 3 Continues on next page 200 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the axis 1 cassette sealing Continued ...

Page 201: ...001108 Loosen the cable bracket from the frame by removing the screw 6 Removing the cable harness from the base Note Action Pull out the robot cable harness through the protection tube 1 Continues on next page Product manual IRB 5720 201 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the axis 1 cassette sealing Continued ...

Page 202: ...ction xx2100002214 Floor mounted robot Loosen the protection tube by removing the two screws underneath Let the tube slide down 1 Continues on next page 202 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the axis 1 cassette sealing Continued ...

Page 203: ...by removing the attachment screws 3 Removing the sealing ring in the frame Note Action Only for floor mounted robot 1 Foundry Plus Cut the flange sealant at the sealing ring protec tion tube Continues on next page Product manual IRB 5720 203 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the axis 1 cassette sealing Continued ...

Page 204: ... mounting tool to the frame Make sure the tool is centered correctly 1 xx2100002215 Fit the second part of the mounting tool 2 xx2100002216 Drill three holes in the old cassette sealing through the holes in the tool Use a drill 3 5 mm 3 Continues on next page 204 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the axis 1 cassette se...

Page 205: ...e two en closed press out screws Screw down the screws alternately 5 xx2100002219 Remove the cassette sealing and the tool Clean the area from metal shavings with a magnet or a vacuum cleaner 6 Continues on next page Product manual IRB 5720 205 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the axis 1 cassette sealing Continued ...

Page 206: ...ng in the frame 1 Lubricate the mounting surfaces in the frame with grease 2 Replacement tool for cassette sealing 3HAC079880 001 xx2100001188 Fit the first part of the mounting tool to the frame 3 xx2100001189 Fit the cassette sealing on the tool with the plain side facing upwards groove down wards 4 Continues on next page 206 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB A...

Page 207: ...as reached the bottom all the way around Remove the mounting tool 7 xx2100001193 Verify that the cassette sealing is fitted evenly by measuring the distance A between the painted edge of the frame and down to the sealing at four 4 locations The measurement is approximately 16 mm 8 Continues on next page Product manual IRB 5720 207 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 ...

Page 208: ...ealing as shown in the figure 9 xx2100001172 Sealant grey 3HAC026759 001 Only for floor mounted robot with protec tion type Foundry Plus 10 Sikaflex 521FC Apply sealant to the mounting surface for the sealing ring Protection type Foundry Plus Not required for option Inverted 3317 1 xx2100001173 Continues on next page 208 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All righ...

Page 209: ...protection tube Note Action xx2100002214 Floor mounted robot Lift the protection tube and secure with the two screws from below 1 Torx pan head screw M6x16 A4 80 2 pcs xx2100002493 Option Inverted 3317 1 Refit the adapter with the attachment screws 2 Continues on next page Product manual IRB 5720 209 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the axis...

Page 210: ...the cables through the protection tube 1 xx1300000736 Make sure that the cables are not twisted Each cable must be in line with its position on the base plate Make sure that the R1 SMB cable will run on the correct side of the R1 MP1 see the figure 2 Make sure that the markings on the cables are facing the base cover when connected 3 Continues on next page 210 Product manual IRB 5720 3HAC079195 00...

Page 211: ...on M6x16 Connect the earth cable 5 Washer dimension 6 4x17x3 Tightening torque 10 Nm xx2100000982 Torx pan head screw M6x16 Stainless steel A2 70 Refit the base cover 6 Tightening torque 10 Nm xx2100000981 Continues on next page Product manual IRB 5720 211 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the axis 1 cassette sealing Continued ...

Page 212: ...racket to the frame 1 Tightening torque 6 Nm xx2100001108 DANGER Make sure all safety requirements are met when performing the first test run 2 212 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the axis 1 cassette sealing Continued ...

Page 213: ...the arm house cover including the cassette sealing Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 5720 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC073375 003 Graphite White 3HAC070735 004 ABB Orange Arm house cover including cas sette sealing Required service parts No...

Page 214: ...878 001 Replacement tool for arm house cover Content is defined in section Standard toolkit on page 596 Standard toolkit Removing the arm house cover including the cassette sealing Use these procedures to remove the arm house cover including the cassette sealing Preparations before removing the arm house cover Note Action See Draining the axis 4 gearbox on page 166 Drain the axis 4 gearbox 1 Conti...

Page 215: ...is 1 0 Axis 2 0 Axis 3 0 Axis 4 0 Axis 5 90 Axis 6 No significance Note The specified position is a recommended position for service Axis 5 must be oriented as close as possible to 90 to be able to open the axis 6 motor cover and to remove the axis 6 motor cables and in order to avoid the spiral of the cable harness in the carrier being unwound or placed in the wrong position Depending on what too...

Page 216: ... xx2000000373 Remove the wrist cover 2 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 216 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Con...

Page 217: ...0 2 6 IRB 5720 155 2 6 LID xx2100002495 Remove the motor cover by removing the screws 3 IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002494 Continues on next page Product manual IRB 5720 217 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Continued ...

Page 218: ... Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx2000000376 Unscrew the attachment screws and re move the motor cover 2 xx2000000375 Remove the connector bracket 3 Disconnect the motor cables 4 Continues on next page 218 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm h...

Page 219: ...rier 6 xx1300001113 Pull out the carrier from its position 7 xx1300000666 Pull out the axis 6 motor cables by holding the cables with one hand at the motor and the other at the carrier 8 Continues on next page Product manual IRB 5720 219 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Continued ...

Page 220: ...nd carrier into a bundle if not already done This is done to facilitate the removal and to avoid damaging the parts This will also make it easier to run the cable harness through the inside of the upper arm 2 xx2000000420 Remove the side cover on the arm tube 3 Continues on next page 220 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 Replaci...

Page 221: ...e screw is reached from outside the up per arm 4 xx1700000339 xx2100002154 Remove the arm house metal clamp 5 Continues on next page Product manual IRB 5720 221 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Continued ...

Page 222: ...rson 1 working at side hole xx2000000416 Remove the cable harness out of the arm tube at the back of the upper arm Tip This step is best performed by two persons working together Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Move the cable harness out of the arm tube 7 Person 2 working at ...

Page 223: ...g the middle screw to the part of the tool designed as a cross all the way until it bottoms 2 xx2100001243 Fit the cross to the tube shaft with four M8 screws 3 xx2100001254 Fit the three armed tool part with three screws and wing nuts 4 Continues on next page Product manual IRB 5720 223 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover i...

Page 224: ... 7 WARNING Used oil is hazardous material and must be dis posed of in a safe way See Decommissioning on page 587 for more information Remove the tool from the arm house cover The tool on the tube shaft can stay fitted 8 Refitting the arm house cover including the cassette sealing Use these procedures to refit the arm house cover including the cassette sealing Preparations before refitting the arm ...

Page 225: ...o the arm house cover to hold the cassette sealing in place during refitting of cover 1 xx2100001267 Fit the three armed tool part with three screws 2 xx2100001265 Prepare the refitting tool by removing the middle screw from the part of the tool designed as a cross 3 Continues on next page Product manual IRB 5720 225 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 R...

Page 226: ...e by rotating the screw Check that the guide pins are inserted in the arm house 6 Torx pan head screw M6x16 Stainless steel A2 70 Secure the cover with the attachment screws Use locking liquid 7 Locking liquid 3HAC041807 004 Loctite 2400 Ensure gap closure between cover and arm house Tightening torque 10 Nm xx2100001255 Remove the tool 8 Continues on next page 226 Product manual IRB 5720 3HAC07919...

Page 227: ...eel A2 70 Fit the cable guide with attachment screws Use locking liquid 2 Locking liquid 3HAC041807 004 Loctite 2400 xx2100001242 Refitting the cable harness to the upper arm Note Action Torx pan head screw M6x16 Stainless steel A2 70 Refit the metal clamp beneath the arm house 1 Tightening torque 10 Nm xx2100002154 Continues on next page Product manual IRB 5720 227 3HAC079195 001 Revision A Copyr...

Page 228: ...guide and then into and through the upper arm tube Tip This step is best performed by two persons working together Person 1 Put one hand inside the side hole of the arm tube and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Use caution and move the cable harness into the arm tube 3 Person 2 working at the back xx1700001569 Continues on...

Page 229: ...ogether Move the cable harness past the axis 5 motor and into the wrist 4 Person 2 working at the wrist xx1300000746 Torx pan head screw M6x16 Stainless steel A2 70 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm 5 Tightening torque 10 Nm xx2000000418 xx2000000417 Continues on next page Product manual IRB 5720 229 3HAC079195 001 Revision A Co...

Page 230: ...o avoid deformation Foundry Plus xx2100002636 DressPack xx2100002679 Connecting the axis 5 motor cables Note Action Put the motor cables in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 Refit the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Tightening torque 1 Nm Secure the power connector with a scre...

Page 231: ... IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100002317 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 6 Continues on next page Product manual IRB 5720 231 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Continued ...

Page 232: ...able for variants IRB 5720 180 2 6 IRB 5720 155 2 6 LID Tightening torque 6 Nm Use locking liquid IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002495 IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002494 Continues on next page 232 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Co...

Page 233: ...sible for a correct installation of the cable harness in the wrist If not connect the brake release tool to the axis 5 motor connector release the brakes and move axis 5 manually to 90 1 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 2 Continues on next page Product manual IRB 5720 233 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repai...

Page 234: ...16 Stainless steel A2 70 Secure the cable bracket with its attach ment screws 5 Tightening torque see standard torque in Screw joints on page 592 xx1300000484 Connect the motor cables 6 Connect in accordance with the markings on the connectors Tightening torque 1 Nm Secure the power connector to the connect or bracket with a screw 7 Continues on next page 234 Product manual IRB 5720 3HAC079195 001...

Page 235: ...e 9 Gasket tilt housing cover Inspect the gasket 10 IRB 5720 180 2 6 IRB 5720 155 2 6 LID Replace if damaged 3HAC074482 001 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC071520 001 xx2100001287 Continues on next page Product manual IRB 5720 235 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cover including the axis 4 cassette sealing Continued ...

Page 236: ...ist cover Note Action IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002627 Make sure that the cable harness is routed and secured as shown in the figure 1 IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002626 IRB 5720 180 2 6 IRB 5720 155 2 6 LID Continues on next page 236 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 5 1 Replacing the arm house cove...

Page 237: ...less steel A2 70 Refit the wrist cover and secure with screws 3 Tightening torque 10 Nm xx2000000373 Concluding procedure Note Action See Filling oil into the axis 4 gearbox on page 168 Refill oil to the axis 4 gearbox 1 See Calibration on page 557 Calibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 Product manual IRB 5720 237 3HAC079195 001 ...

Page 238: ...are part L2 Complete unit with motors and gears IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC074235 002 Graphite White 3HAC074235 003 ABB Orange IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072470 002 Graphite White 3HAC072470 004 ABB Orange Wrist Required tools and equipment Note Article number Equipment User instructions are enclosed with the tool 3HAC081310 001 Brake release tool Continues on next pag...

Page 239: ...aphite White 3HAC074181 004 ABB Orange IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC073390 002 Graphite White 3HAC073390 004 ABB Orange Wrist cover Polyamide 6 6 21662055 3 Cable strap out door 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...

Page 240: ...e robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the wrist Use these procedures to remove the wrist Preparations before removing the wrist Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 Remove tools and other equipment fitted to the wrist 2 xx...

Page 241: ...ressure are turned off 1 xx2000000373 Remove the wrist cover 2 Disconnecting the axis 6 motor cables 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 5720 241 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 242: ...75 Remove the connector bracket 3 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws that hold the cable bracket 5 Continues on next page 242 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 243: ...6 motor cables by holding the cables with one hand at the motor and the other at the carrier 8 Disconnecting the axis 5 motor cables 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 5720 243 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the w...

Page 244: ...xx2100002625 IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002495 Remove the motor cover by removing the screws 3 IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002494 Continues on next page 244 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 245: ... a roundsling to the wrist as shown in the figure CAUTION The roundsling placement shown in the figure keeps the wrist balanced when lifted which reduces risk of damage or injury Do not attach the roundsling around the axis 5 gearbox 2 Stretch the roundsling so it carries the weight of the wrist 3 Removing the wrist Note Action xx2100001289 Remove the attachment screws 1 Pull out the wrist a bit a...

Page 246: ...ool 1 Turn off the brake release tool 2 Connect the tool to the R2 MP5 connector 3 Release the brakes by turning on the brake release tool and pressing the brake release button on the tool DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool Roundsling 1 m Length 1 m xx2100001291 Attach a roundsling to the wrist as shown in the figu...

Page 247: ...que in Screw joints on page 592 Tighten the attachment screws 4 Connecting the axis 5 motor cables Note Action Put the motor cables in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 Refit the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Tightening torque 1 Nm Secure the power connector with a screw 4 C...

Page 248: ...s damaged 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100002317 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 6 Continues on next page 248 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 249: ...able protection is available for variants IRB 5720 180 2 6 IRB 5720 155 2 6 LID Tightening torque 6 Nm Use locking liquid IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002495 IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002494 Continues on next page Product manual IRB 5720 249 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 250: ...on 90 or as close as possible for a correct installation of the cable harness in the wrist If not connect the brake release tool to the axis 5 motor connector release the brakes and move axis 5 manually to 90 1 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 2 Continues on next page 250 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All...

Page 251: ... Torx pan head screw M6x16 Stainless steel A2 70 Secure the cable bracket with its attach ment screws 5 Tightening torque see standard torque in Screw joints on page 592 xx1300000484 Connect the motor cables 6 Connect in accordance with the markings on the connectors Tightening torque 1 Nm Secure the power connector to the connect or bracket with a screw 7 Continues on next page Product manual IRB...

Page 252: ...ut as shown in the figure 9 Gasket tilt housing cover Inspect the gasket 10 IRB 5720 180 2 6 IRB 5720 155 2 6 LID Replace if damaged 3HAC074482 001 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC071520 001 xx2100001287 Continues on next page 252 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 6 1 Replacing the wrist Continued ...

Page 253: ...0000376 Refitting the wrist cover Note Action IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002627 Make sure that the cable harness is routed and secured as shown in the figure 1 IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002626 IRB 5720 180 2 6 IRB 5720 155 2 6 LID Continues on next page Product manual IRB 5720 253 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 6 1 Repl...

Page 254: ...ange xx2100001407 Torx pan head screw M6x16 Stainless steel A2 70 Refit the wrist cover and secure with screws 3 Tightening torque 10 Nm xx2000000373 Concluding procedure Note Action Foundry Plus 1 Refit protection plugs See Calibration on page 557 Calibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 254 Product manual IRB 5720 3HAC079195 001 ...

Page 255: ...s shown in the figure IRB 5720 180 2 6 xx2100002166 IRB 5720 125 3 0 xx2100002260 IRB 5720 155 2 6 LID IRB 5720 90 3 0 LID xx2100002628 Continues on next page Product manual IRB 5720 255 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the turning disc ...

Page 256: ...ck 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 create new reference values These val ...

Page 257: ... air pressure supply to the robot before entering the safeguarded space 2 Remove any equipment fitted to the turning disc 3 Removing the turning disc Note Action IRB 5720 180 2 6 IRB 5720 125 3 0 xx2100002167 Remove the screws and washers that se cure the turning disc 1 IRB 5720 155 2 6 LID IRB 5720 90 3 0 LID TBD Continues on next page Product manual IRB 5720 257 3HAC079195 001 Revision A Copyrig...

Page 258: ...the contact surfaces 1 Rust preventive 3HAC034903 001 Mercasol 3110 Waxcoat Recom mended drying time is 24h xx2100002232 Protection type Foundry Plus Apply rust preventive to the surface shown in the figure 2 Continues on next page 258 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 6 2 Replacing the turning disc Continued ...

Page 259: ...3 0 LID Washer 3HAB4233 1 IRB 5720 180 2 6 IRB 5720 155 2 6 LID 9 pcs IRB 5720 125 3 0 IRB 5720 90 3 0 LID Steel 8 4x13x1 5 Tightening torque see standard torque in Screw joints on page592 IRB 5720 180 2 6 IRB 5720 125 3 0 xx2100002167 IRB 5720 155 2 6 LID IRB 5720 90 3 0 LID TBD Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run 1 ...

Page 260: ...See the latest spare parts of the IRB 5720 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC071396 001 Cable harness Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 596 Standard toolkit Continues on next page 260 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights re...

Page 261: ...rted 3317 1 Jog the robot to the specified position Axis 1 0 Axis 2 0 Axis 3 0 Axis 4 0 Axis 5 90 Axis 6 No significance Note The specified position is a recommended position Orient axis 5 as close as possible to 90 to be able to open the axis 6 motor cover and to remove the axis 6 motor cables The axis 5 position is also important to avoid the spiral of the cable harness in the carrier being unwo...

Page 262: ... remove the cable harness in the upper arm and wrist Retrieving access to the wrist cabling Use this procedure to remove the wrist cover Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 262 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing th...

Page 263: ... 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 5720 263 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 264: ...emove the connector bracket 3 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws that hold the cable bracket 5 Continues on next page 264 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 265: ...tor cables by holding the cables with one hand at the motor and the other at the carrier 8 Disconnecting the axis 5 motor cables 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 5720 265 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable ...

Page 266: ...00002625 IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002495 Remove the motor cover by removing the screws 3 IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002494 Continues on next page 266 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 267: ...DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx2100000596 Remove the motor cover by removing the screws 2 xx2100000667 Disconnect the power cable connector by removing the attachment screw 3 Disconnect the signal cable connector 4 Continues on next page Product manual IRB 5720 267 3HAC079195 001 Revision A Copyright 2022 ABB All right...

Page 268: ...arness from the wrist and upper arm Note Action Foundry Plus xx2000000422 Foundry Plus DressPack Remove the cover Note Use caution not to damage the gasket 1 DressPack Continues on next page 268 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 269: ...tate the removal and to avoid damaging the parts This will also make it easier to run the cable harness through the inside of the upper arm 2 xx2000000420 Remove the side cover on the arm tube 3 Continues on next page Product manual IRB 5720 269 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 270: ... the arm tube Note The screw is reached from outside the up per arm 4 xx1700000339 xx2100002154 Remove the arm house metal clamp 5 Continues on next page 270 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 271: ...wrist xx1300000746 Person 1 working at side hole xx2000000416 Remove the cable harness out of the arm tube at the back of the upper arm Tip This step is best performed by two persons working together Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Move the cable harness out of the arm tube 7...

Page 272: ... in the base Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx2100000981 Remove the base cover 2 xx2100001109 Loosen the connectors R1 MP R1 SMB 3 Continues on next page 272 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 273: ...e bracket from the frame by removing the screw 6 Disconnecting the axis 1 and axis 2 motor cables 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 5720 273 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 274: ...667 Disconnect the power cable connector by removing the attachment screw 3 Disconnect the signal cable connector 4 Continues on next page 274 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 275: ...re supply air pressure supply to the robot before entering the safeguarded space 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 52 2 Continues on next page Product manual IRB 5720 275 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harn...

Page 276: ...ive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 52 1 Disconnect all connectors from the SMB board 2 Disconnect the connectors R2 BU1 and R2 BU2 from the brake release board 3 Removing the cable harness from the base Note Action xx2100001111 Pull out the robot cable harness through the protection tube 1 Place the cable harness safely o...

Page 277: ...ble harness from the lower arm Note Action xx2100002182 Loosen the upper and lower cable clamps inside the lower arm by removing the attach ment screws Note The screws are reached from the outside of the lower arm 1 xx2100002183 Continues on next page Product manual IRB 5720 277 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 278: ...02139 Remove the arm house metal clamp from the harness Continues on next page 278 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 279: ...2100002144 Use caution and pull the cable harness out 3 Option Inverted 3317 1 xx2100002140 Product manual IRB 5720 279 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 1 Removing the cable harness Continued ...

Page 280: ...f the IRB 5720 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC071396 001 Cable harness Required service parts Note Article number Consumable Polyamide 6 6 21662055 3 Cable strap outdoor 3HAC033886 001 Metal strap Loctite 2400 3HAC041807 004 Locking liquid Continues on next page 280 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rig...

Page 281: ...25 3 0 IRB 5720 90 3 0 LID 3HAC073918 003 Graphite White 3HAC073918 004 ABB Orange Tilt housing cover with gasket Replace if damaged IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC074181 002 Graphite White 3HAC074181 004 ABB Orange IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC073390 002 Graphite White 3HAC073390 004 ABB Orange Wrist cover Replace if damaged 3HAC073671 001 Gasket for cover electronics Requi...

Page 282: ...arrier into a bundle if not already done This is done to facilitate the procedure and to avoid damaging the parts during the procedure This will also make it easier to run the cable harness through the inside of the robot 1 xx2100002139 Remove the arm house metal clamp from the harness if installed 2 Continues on next page 282 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB Al...

Page 283: ...un the cable harness through the lower arm 3 Option Inverted 3317 1 xx2100002185 Continues on next page Product manual IRB 5720 283 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 284: ...htening torque 6 Nm xx2100002182 Note Check that the cabling will stay a little bit twisted between the cable clamps Do not change the position of the brackets xx1300000595 xx2100002183 xx2100002139 Refit the arm house metal clamp to the harness 5 Continues on next page 284 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable h...

Page 285: ...run on the correct side of the R1 MP1 see the figure 2 Make sure that the markings on the cables are facing the base cover when connected 3 Screw dimension for R1 MP M6x25 A2 70 Connect connectors R1 MP and R1 SMB 4 Tightening torque for R1 MP 10 Nm Tightening torque for R1 SMB 10 Nm xx2100001109 Continues on next page Product manual IRB 5720 285 3HAC079195 001 Revision A Copyright 2022 ABB All ri...

Page 286: ...g torque 10 Nm xx2100000981 Reconnecting the SMB and BU units 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 52 1 Continues on next page 286 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Cont...

Page 287: ...is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 52 1 Gasket for cover electronics 3HAC073671 001 Check the electronic box gasket Replace if damaged 2 Torx pan head screw M6x60 5 pcs Refit the electronic box with the attachment screws 3 Tightening torque 10 Nm xx2100002134 Continues on next page Product manual IRB 5720 287 3HA...

Page 288: ...ts to the frame 1 Tightening torque 6 Nm xx2000000442 xx2100001108 Metal strap 3HAC033886 001 xx2100002133 Secure the cable at the frame with metal straps 2 Continues on next page 288 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 289: ...0598 Refit the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Tightening torque 1 Nm xx2100000667 Secure the power connector with a screw 4 Continues on next page Product manual IRB 5720 289 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 290: ...BB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Axis 5 Connection box cover with gasket gasket not needed for protection type Standard IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will ...

Page 291: ... Torx pan head screw M6x16 Stainless steel A2 70 Refit the metal clamp beneath the arm house 1 Tightening torque 10 Nm xx2100002154 xx1300000668 Tip Use tape and tie the axis 5 and axis 6 connectors and carrier into a bundle if not already done This is done to facilitate the procedure and to avoid damaging the parts during the procedure This will also make it easier to run the cable harness throug...

Page 292: ...3 Person 2 working at the back xx1700001569 Person 1 working at the side hole xx2000000416 Use caution and push the cable harness into the wrist Tip This step is best performed by two persons working together Person 1 Put one hand inside the side cover hole and take a hold of the cable harness Person 2 Take a hold of the cable harness from inside the wrist Together Move the cable harness past the ...

Page 293: ...e 10 Nm xx2000000418 xx2000000417 xx2000000420 Refit the side cover Note Foundry Plus Make sure the gasket is fitted cor rectly on the side cover Use attachment screws made of stainless steel to fit the side cover 6 Continues on next page Product manual IRB 5720 293 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 294: ...s 7 Tightening torque 10 Nm Tighten the two screws closest to the outlet first shown in figure to avoid deformation Foundry Plus xx2100002636 DressPack xx2100002679 Continues on next page 294 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 295: ...0598 Refit the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Tightening torque 1 Nm xx2100000667 Secure the power connector with a screw 4 Continues on next page Product manual IRB 5720 295 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 296: ...BB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Axis 5 Connection box cover with gasket gasket not needed for protection type Standard IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will ...

Page 297: ... Put the motor cables in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 Refit the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Tightening torque 1 Nm Secure the power connector with a screw 4 Continues on next page Product manual IRB 5720 297 3HAC079195 001 Revision A Copyright 2022 ABB All rights rese...

Page 298: ...maged 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100002317 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 6 Continues on next page 298 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 299: ... protection is available for variants IRB 5720 180 2 6 IRB 5720 155 2 6 LID Tightening torque 6 Nm Use locking liquid IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002495 IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002494 Continues on next page Product manual IRB 5720 299 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 300: ...0 or as close as possible for a correct installation of the cable harness in the wrist If not connect the brake release tool to the axis 5 motor connector release the brakes and move axis 5 manually to 90 1 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 2 Continues on next page 300 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rig...

Page 301: ...x pan head screw M6x16 Stainless steel A2 70 Secure the cable bracket with its attach ment screws 5 Tightening torque see standard torque in Screw joints on page 592 xx1300000484 Connect the motor cables 6 Connect in accordance with the markings on the connectors Tightening torque 1 Nm Secure the power connector to the connect or bracket with a screw 7 Continues on next page Product manual IRB 572...

Page 302: ...s shown in the figure 9 Gasket tilt housing cover Inspect the gasket 10 IRB 5720 180 2 6 IRB 5720 155 2 6 LID Replace if damaged 3HAC074482 001 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC071520 001 xx2100001287 Continues on next page 302 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 303: ...376 Refitting the wrist cover Note Action IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002627 Make sure that the cable harness is routed and secured as shown in the figure 1 IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002626 IRB 5720 180 2 6 IRB 5720 155 2 6 LID Continues on next page Product manual IRB 5720 303 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refittin...

Page 304: ...BB Orange xx2100001407 Torx pan head screw M6x16 Stainless steel A2 70 Refit the wrist cover and secure with screws 3 Tightening torque 10 Nm xx2000000373 Concluding procedure Note Action Torx pan head screw M6x16 Stainless steel A2 70 Refit the metal clamp on top of the arm house 1 Tightening torque 10 Nm xx2100001285 Continues on next page 304 Product manual IRB 5720 3HAC079195 001 Revision A Co...

Page 305: ...trap 2 See Updating revolution counters on page 563 Update the revolution counters 3 DANGER Make sure all safety requirements are met when performing the first test run 4 Product manual IRB 5720 305 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 2 Refitting the cable harness Continued ...

Page 306: ...l www abb com myABB Level Note Article number Spare part L2 3HAC073540 001 Brake release unit Required service parts Note Article number Consumable Replace if damaged 3HAC073671 001 Gasket for cover electronics Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 596 Standard toolkit Continues on next page 306 Product manual IRB 5720 3HA...

Page 307: ...D on page 52 2 xx2100002134 Remove the electronic box screws 3 xx2100002135 Remove the electronic box including all internal equipment CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Disconnecting and removing the SMB unit Note Action DANGER Make sure that all supplies for electrical power hy draulic pr...

Page 308: ...g and removing the brake release unit Note Action DANGER Make sure that all supplies for electrical power hy draulic 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 52 2 Disconnect the connectors R2 BU1 and R2 BU2 from the brake release board 3 Co...

Page 309: ...teel Fe Zn 8c M6x16 Fit brake release unit into the electronic box and se cure with the screws 2 Tightening torque 10 Nm xx2100002163 Refitting and connecting the SMB unit 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 informati...

Page 310: ...ng screw Steel Fe Zn 8c M6x16 Secure the SMB unit with the attachment screws 4 Tightening torque 10 Nm xx2100002159 Continues on next page 310 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 3 Replacing the brake release unit Continued ...

Page 311: ...itive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 52 1 Reconnect the connectors R2 BU1 and R2 BU2 to the brake release board 2 Refitting the electronic box 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 52 1 Gaske...

Page 312: ...te Action See Updating revolution counters on page 563 Update the revolution counters if the battery has been disconnected 1 DANGER Make sure all safety requirements are met when performing the first test run 2 312 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 3 Replacing the brake release unit Continued ...

Page 313: ...m myABB Level Note Article number Spare part L2 3HAC043904 001 Serial measurement unit Required service parts Note Article number Consumable Replace if damaged 3HAC073671 001 Gasket for cover electronics Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 596 Standard toolkit Continues on next page Product manual IRB 5720 313 3HAC079195...

Page 314: ...o ESD on page 52 2 xx2100002134 Remove the electronic box screws 3 xx2100002135 Remove the electronic box including all internal equipment CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Disconnecting and removing the SMB unit Note Action DANGER Make sure that all supplies for electrical power hy drauli...

Page 315: ...the unit in an ESD bag 5 Refitting the SMB unit Refitting and connecting the SMB unit 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 52 2 Continues on next page Product...

Page 316: ...tapping screw Steel Fe Zn 8c M6x16 Secure the SMB unit with the attachment screws 4 Tightening torque 10 Nm xx2100002159 Continues on next page 316 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 4 Replacing the SMB unit Continued ...

Page 317: ...ng the electronic box 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 52 1 Gasket for cover electronics 3HAC073671 001 Check the electronic box gasket Replace if damaged 2 Torx pan head screw M6x60 5 pcs Refit the electronic box with the attachment screws 3 Tightening torque 10...

Page 318: ...n page 563 Update the revolution counters 1 DANGER Make sure all safety requirements are met when performing the first test run 2 318 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 7 4 Replacing the SMB unit Continued ...

Page 319: ...n the manipulator from inverted to floor standing position on page 195 Location of the motor The motor is located as shown in the figure xx2000000241 Summary of the replacement procedure This list is a brief summary of the replacement procedure containing the major actions to be performed 1 If installed in an inverted position option 3317 1 drain the axis 1 gearbox 2 Replace the motor Continues on...

Page 320: ...losed with the tool 3HAC073537 001 Lifting and turning tool User instructions are enclosed with the tool 3HAC081310 001 Brake release tool Used to rotate the motor pinion 3HAB7887 1 Rotation tool Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot 3HAC074564 001 axes 1 2 3 and 4 3HAC074119 001 axes 5 and 6 Calibration toolbox Axis Cali...

Page 321: ...t reference calibration for Axis Calibration in Reference calibration routine on page 566 If no previous reference values exist and no new reference values can 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 motor P...

Page 322: ... turned off 1 xx2100000596 Remove the motor cover by removing the screws 2 xx2100000667 Disconnect the power cable connector by removing the attachment screw 3 Disconnect the signal cable connector 4 Continues on next page 322 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 motor Continued ...

Page 323: ...nted robot Removing the axis 1 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 5720 323 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 motor Continued ...

Page 324: ...ollow enclosed user instructions for the tool 2 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk Bits extender 3HAC12342 1 xx2100000503 Unscrew the attachment screws and washers Use a bits extender to reach the scre...

Page 325: ... if excess ive force is used 6 Removal tool motor M12 3HAC14631 1 Press the motor out of its position by using the removal tool in opposite holes of the motor 7 Always use removal tools in pairs xx2100002186 Use caution and lift the motor straight up to get the pinion parted from the gear 8 Disconnect the brake release tool 9 Continues on next page Product manual IRB 5720 325 3HAC079195 001 Revisi...

Page 326: ...helf beneath the motor while fastening the tool 1 xx2100002808 Secure the tool to the robot frame with the attach ment screws 2 Screw the revolving handle to lift and fit the shelf against the motor 3 Inverted robot Removing the axis 1 motor Note This procedure is valid for inverted robots Continues on next page 326 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights re...

Page 327: ...AC12342 1 xx2100002810 Remove the two shown motor screws and wash ers 1 xx2100002809 Raise the revolving handle to fit the motor on the tool shelf CAUTION Risk of pinching Do not pinch the motor cabling Route the cables throughout the motor connector hole 2 Continues on next page Product manual IRB 5720 327 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing t...

Page 328: ...p remove the motor 5 Always use removal tools in pairs Rotate the shelf to remove the motor CAUTION The weight of the motor is 21 kg All lifting accessories used must be sized accord ingly 6 Lift away the motor 7 Refitting the motor Use these procedures to refit the motor Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure an...

Page 329: ...emove the cover if fitted to the new spare part motor 4 Tightening torque transparent plug 20 Nm Protection type Foundry Plus Valid for axis 1 axis 2 axis 3 and axis 4 5 Tightening torque protection filter 20 Nm xx1600000576 If the motor is a new spare part the evacuation hole protection filter must be replaced with a transparent plug sight glass enclosed with the spare part delivery Remove the pr...

Page 330: ... connector 3 Release the brakes by pressing the button on the tool DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 4 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the specified brake release tool t...

Page 331: ...motor with its attachment screws and washers Use a bits extender to reach the screws 7 Bits extender 3HAC12342 1 Tightening torque 50 Nm xx2100000503 Disconnect the brake release tool 8 See Performing a leak down test on page 188 Perform a leak down test if not already done 9 Inverted robot Attaching the motor lifting accessory Note This procedure is valid for inverted robots Continues on next pag...

Page 332: ...the robot frame with the attach ment screws 2 Screw the revolving handle to lift and fit the shelf against the motor 3 Inverted robot Refitting the axis 1 motor Note Action CAUTION The weight of the motor is 21 kg All lifting accessories used must be sized accord ingly 1 Continues on next page 332 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8...

Page 333: ...pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 3 xx2100002815 Put the motor on the tool shelf and rotate it into position CAUTION Risk of pinching Do not pinch the motor cabling Route the cables throughout the motor connector hole 4 xx2100002809 Figure 5 1 Raise the revolving handle to assemble motor Make sure that the motor pinion is properly mated to the gear in the gearbox Make sure t...

Page 334: ...1 See Performing a leak down test on page 188 Perform a leak down test if not already done 7 Disconnect the brake release tool 8 Inverted robot Removing the motor lifting accessory Note Action xx2100002808 Remove the lifting accessory by removing the at tachment screws 1 Continues on next page 334 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8...

Page 335: ...t the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Tightening torque 1 Nm xx2100000667 Secure the power connector with a screw 4 Continues on next page Product manual IRB 5720 335 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 motor Continued ...

Page 336: ...ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Axis 5 Connection box cover with gasket gasket not needed for protection type Standard IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will...

Page 337: ...ent and secure the robot inverted Note Action See user instructions enclosed with the fork lift accessory set Install the fork lift pockets to the robot DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 1 Fork lift accessory set 3HAC058825 001 Continues on next page Product manual IRB 5720 337 3HAC079195 001 Revision A Copyright ...

Page 338: ...se to its installation location 4 Lifting and turning tool 3HAC073537 001 Rotate the robot into inverted position using the turning tool or using a fork lift truck with a rotator attachment DANGER Make sure that there is enough space underneath the robot See user instructions for the turning tool 5 See user instructions enclosed with the turning tool Guide the robot using two attachment screws whi...

Page 339: ...edure Use this procedure for the concluding refitting Note Action See Calibration on page 557 Re calibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 5720 339 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 1 Replacing the axis 1 motor Continued ...

Page 340: ... arm 3 Replace the motor Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 5720 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC074201 003 Graphite White 3HAC074201 004 ABB Orange Motor unit including connection box Continues on next page 340 Product manual IRB 5720 3HAC0791...

Page 341: ...HAC15521 2 Guide pin M10x150 Used to push out the motor if necessary Always use removal tools in pairs 3HAC14631 1 Removal tool motor M12 Lifting instruction 3HAC15640 2 enclosed 3HAC15534 1 Lifting accessory motor Lifting instruction 3HAC15880 2 enclosed 3HAC15556 1 Lifting accessory chain Used to rotate the motor pinion 3HAB7887 1 Rotation tool Delivered as a set of calibration tools Required if...

Page 342: ...ues 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 Reference calibration routine on page 566 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the ro...

Page 343: ...g the oil in axis 2 gearbox on page 154 Drain the oil from the gearbox 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 5 Disconnecting the motor cables 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 man...

Page 344: ...667 Disconnect the power cable connector by removing the attachment screw 3 Disconnect the signal cable connector 4 Continues on next page 344 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 motor Continued ...

Page 345: ...gearbox is completely drained 1 DANGER When releasing the holding brakes of the motor the lower arm will be movable and may fall down if not secured Verify that the lower arm is secured as previously de scribed before continuing 2 Continues on next page Product manual IRB 5720 345 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 motor Continued ...

Page 346: ...ndslings are stretched by raising the overhead crane before releas ing the brakes 3 User instructions are enclosed with the tool xx2100000666 DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brak...

Page 347: ...out of its position by using the removal tool in opposite holes of the motor 7 Used to push out the motor if necessary Always use removal tools in pairs CAUTION The weight of the motor is 25 kg All lifting accessories used must be sized accordingly 8 xx2000000457 Carefully lift the motor out on the guide pins in order to get the pinion away from the gear and let it rest on the guide pins 9 Disconn...

Page 348: ...itting the motor Use these procedures to refit the axis 2 motor Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove any old paint or flange sealant residues or other contamination from the contact surfaces on both the motor and the mating parts Tip Remove flange sealant residues with L...

Page 349: ...us Valid for axis 1 axis 2 axis 3 and axis 4 5 Tightening torque protection filter 20 Nm xx1600000576 If the motor is a new spare part the evacuation hole protection filter must be replaced with a transparent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass xx1800000102 Transparent plug Foundry Plus xx1800000101 Protec...

Page 350: ...ght of the motor is 25 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC15534 1 Apply the lifting accessory 3 Lifting accessory chain 3HAC15556 1 xx2100000594 Continues on next page 350 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 motor Continued ...

Page 351: ... as close as possible to its final position without pushing the motor pinion into the gear 5 xx2000000457 Remove the lifting accessory and allow the motor to rest on the guide pins 6 Continues on next page Product manual IRB 5720 351 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 motor Continued ...

Page 352: ...g mating motor and gear box the gears may be damaged if excess ive force is used 8 Rotation tool 3HAB7887 1 Apply the rotation tool 9 Use caution and fit the motor in its final position while at the same time rotating the motor pinion slightly using the rotation tool Make sure that the motor pinion is properly mated to the gear of the gearbox Make sure that the motor pinion does not get damaged Ma...

Page 353: ...g attachment screws 11 Tightening torque 50 Nm Tighten the screws 12 Disconnect the brake release tool 13 See Performing a leak down test on page 188 Perform a leak down test 14 Continues on next page Product manual IRB 5720 353 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 motor Continued ...

Page 354: ...t the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Tightening torque 1 Nm xx2100000667 Secure the power connector with a screw 4 Continues on next page 354 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 2 Replacing the axis 2 motor Continued ...

Page 355: ...ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Axis 5 Connection box cover with gasket gasket not needed for protection type Standard IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will...

Page 356: ...e to facilitate the removal of the lock screw that secures the lower arm 1 xx2100000592 Remove the lock screw 2 See Filling oil into the axis 2 gear box on page 157 Refill the gearbox with oil 3 See Calibration on page 557 Re calibrate the robot 4 DANGER Make sure all safety requirements are met when performing the first test run 5 356 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 20...

Page 357: ...aphite White 3HAC073868 004 ABB Orange Motor unit Required service parts Note Article number Consumable See Type of lubrication in gear boxes on page 141 Lubricating oil Loctite 5800 3HAC041807 007 Flange sealant Replace if damaged 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Connection box cover FS130 with gasket Used on oil plug Always replace when refitting oil plug 3HACxxx O ring Co...

Page 358: ...s the valid calibration method for the robot 3HAC074564 001 axes 1 2 3 and 4 3HAC074119 001 axes 5 and 6 Calibration toolbox Axis Calibra tion Content is defined in section Standard toolkit on page 596 Standard toolkit Removing the motor Use these procedures to remove the motor Preparations before removing the motor Note Action Decide which calibration routine to use and take actions accordingly p...

Page 359: ...ble access to fit the lifting accessories to the upper arm 170 shown in figure Axis 2 47 Axis 3 135 upper arm horizontal Axis 4 0 Axis 5 no significance Axis 6 no significance Unload the weight of the upper arm using one of these methods Use a fork lift to rest the upper arm onto Use lifting slings and an overhead crane to rest the upper arm onto 4 DANGER Turn off all electric power supply hydraul...

Page 360: ...xx2100000596 Remove the motor cover by removing the screws 2 xx2100000667 Disconnect the power cable connector by removing the attachment screw 3 Disconnect the signal cable connector 4 Continues on next page 360 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 motor Continued ...

Page 361: ...e gearbox is completely drained 1 DANGER When releasing the holding brakes of the motor the upper arm will be movable and falls down if not secured Verify that the upper arm is secured as previously de scribed before continuing 2 Continues on next page Product manual IRB 5720 361 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 motor Continued ...

Page 362: ...cause serious injury Read and follow enclosed user instructions for the tool WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk Bits extender 3HAC12342 1 xx2100002153 Remove two opposite attachment screws Use a bits extender in order to reach the screws 4 Guide pin M10x150 3...

Page 363: ...cable gland hole is facing The motor shall be refitted in the same position Make sure the pinion is not damaged Refitting the motor Use these procedures to refit the motor Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove any old paint or flange sealant residues or other contaminatio...

Page 364: ...us Valid for axis 1 axis 2 axis 3 and axis 4 5 Tightening torque protection filter 20 Nm xx1600000576 If the motor is a new spare part the evacuation hole protection filter must be replaced with a transparent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass xx1800000102 Transparent plug Foundry Plus xx1800000101 Protec...

Page 365: ... the axis 3 motor with the brake release tool 1 Make sure the brake release tool is turned off 2 Connect the tool to the R2 MP3 connector 3 Release the brakes by pressing the button on the tool DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 4 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage t...

Page 366: ...the correct way Hex socket head cap screw M10x30 12 9 Gleitmo 603 Geomet 500 2 pcs Fit two of the attachment screws and washers 7 Bits extender 3HAC12342 1 xx2100002152 Use a bits extender in order to reach the screws Hex socket head cap screw M10x30 12 9 Gleitmo 603 Geomet 500 2 pcs xx2100002153 Remove the guide pins and replace with the remaining attachment screws 8 Tightening torque 50 Nm Tight...

Page 367: ...t the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Tightening torque 1 Nm xx2100000667 Secure the power connector with a screw 4 Continues on next page Product manual IRB 5720 367 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 3 Replacing the axis 3 motor Continued ...

Page 368: ...ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Axis 5 Connection box cover with gasket gasket not needed for protection type Standard IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will...

Page 369: ...orx pan head screw M6x16 Stainless steel A2 70 Refit the metal clamp beneath the arm house 2 Tightening torque 10 Nm xx2100002154 See Filling oil into the axis 3 gear box on page 163 Refill the gearbox with oil 3 See Calibration on page 557 Re calibrate the robot 4 DANGER Make sure all safety requirements are met when performing the first test run 5 Product manual IRB 5720 369 3HAC079195 001 Revis...

Page 370: ... com myABB Level Note Article number Spare part L2 3HAC073869 003 Graphite White 3HAC073869 004 ABB Orange Motor unit Required service parts Note Article number Consumable Loctite 5800 3HAC041807 007 Flange sealant Replace if damaged 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Connection box cover FS130 with gasket Continues on next page 370 Product manual IRB 5720 3HAC079195 001 Revis...

Page 371: ...ools Required if Axis Calibration is the valid calibration method for the robot 3HAC074564 001 axes 1 2 3 and 4 3HAC074119 001 axes 5 and 6 Calibration toolbox Axis Calibra tion Content is defined in section Standard toolkit on page 596 Standard toolkit Removing the motor Use these procedures to remove the motor Preparations before removing the motor Note Action Decide which calibration routine to...

Page 372: ...rm pointing straight up if possible Axis 4 no significance Axis 5 no significance Axis 6 no significance With the robot in this position there is no need to drain oil from the axis 4 gearbox when the motor is replaced 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 4 See Draining the axis 4 gearbox on page...

Page 373: ...xx2100000596 Remove the motor cover by removing the screws 2 xx2100000667 Disconnect the power cable connector by removing the attachment screw 3 Disconnect the signal cable connector 4 Continues on next page Product manual IRB 5720 373 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 motor Continued ...

Page 374: ... Removing the axis 4 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 374 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 motor Continued ...

Page 375: ...expectedly 2 User instructions are enclosed with the tool xx2100000666 DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the specified brake release tool to eliminate the risk Continues on next page Product manu...

Page 376: ...rce is used 5 Removal tool motor M12 3HAC14631 1 Press the motor out of its position by using the removal tool in opposite holes of the motor 6 Used to push out the motor if ne cessary Always use removal tools in pairs CAUTION The weight of the motor is 12 kg All lifting accessories used must be sized accord ingly 7 Continues on next page 376 Product manual IRB 5720 3HAC079195 001 Revision A Copyr...

Page 377: ...ant residues or other contamination from the contact surfaces on both the motor and the mating parts Tip Remove flange sealant residues with Loctite 7200 Then use Loctite 7063 for cleaning the mating surface 2 Flange sealant 3HAC041807 007 Loctite 5800 xx2100000520 Apply a continuous bead of flange sealant 1 2 mm wide inside of the groove on the motor con tact surface Note The purpose of the groov...

Page 378: ...h a transparent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Refitting the axis 4 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs xx2100002201 Continues on next page ...

Page 379: ...R2 MP4 connector 3 Release the brakes by pressing the button on the tool DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 4 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release...

Page 380: ...that the motor pinion does not get damaged Make sure that the direction of the cable exit is facing the correct way Hex socket head cap screw M10x30 12 9 Gleitmo 603 Geomet 500 2 pcs Fit two of the attachment screws and washers 7 Bits extender 3HAC12342 1 xx2100002212 Use a bits extender in order to reach the screws Continues on next page 380 Product manual IRB 5720 3HAC079195 001 Revision A Copyr...

Page 381: ...ng attachment screws 8 Tightening torque 24 Nm Tighten the screws 9 Disconnect the brake release tool 10 See Performing a leak down test on page 188 Perform a leak down test 11 Continues on next page Product manual IRB 5720 381 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 motor Continued ...

Page 382: ...t the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Tightening torque 1 Nm xx2100000667 Secure the power connector with a screw 4 Continues on next page 382 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 motor Continued ...

Page 383: ...ABB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Axis 5 Connection box cover with gasket gasket not needed for protection type Standard IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will...

Page 384: ...Concluding procedure Note Action See Filling oil into the axis 4 gear box on page 168 Refill the gearbox with oil if drained 1 See Calibration on page 557 Re calibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 384 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 4 Replacing the axis 4 motor...

Page 385: ...via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC071373 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC070735 003 Motor unit Required service parts Note Article number Consumable Loctite 5800 3HAC041807 007 Flange sealant Continues on next page Product manual IRB 5720 385 3HAC079195 001 Revision A Copyright 2022 ABB All rig...

Page 386: ...LID 3HAC14631 1 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC14972 1 IRB 5720 180 2 6 IRB 5720 155 2 6 LID Removal tool motor M12 IRB 5720 125 3 0 IRB 5720 90 3 0 LID Removal tool motor M10 Used to rotate the motor pinion 3HAB7887 1 Rotation tool Delivered as a set of calibration tools Required if Axis Calibration is the valid calibration method for the robot 3HAC074564 001 axes 1 2 3 and 4 3HAC074119...

Page 387: ...position to replace axis 5 motor for example 0 Axis 4 90 Axis 5 no significance Axis 6 no significance With the robot in this position there is no need to drain oil from the axis 5 gearbox when the motor is replaced 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 4 Retrieving access to the wrist cabling U...

Page 388: ...l power hydraulic pressure and air pressure are turned off 1 IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002630 Cut the cable tie 2 IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002625 Continues on next page 388 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 5 Replacing the axis 5 motor Continued ...

Page 389: ...4 Disconnect the signal cable connector 5 Remove the cable bracket by removing the screws 6 Remove the motor cables 7 Removing the axis 5 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 5720 389 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 5 Repl...

Page 390: ...elease tool to eliminate the risk Bits extender 3HAC12342 1 xx2100002204 Unscrew the attachment screws that secure the motor using a bits extender 3 CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 4 IRB 5720 180 2 6 IRB 5720 155 2 6 LID Press the motor out of its position by using the removal tool in opposite holes of the motor 5 Removal tool m...

Page 391: ...reparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove any old paint or flange sealant residues or other contamination from the contact surfaces on both the motor and the mating parts Tip Remove flange sealant residues with Loctite 7200 Then use Loctite 7063 for cleaning the mating surface...

Page 392: ...us Valid for axis 1 axis 2 axis 3 and axis 4 5 Tightening torque protection filter 20 Nm xx1600000576 If the motor is a new spare part the evacuation hole protection filter must be replaced with a transparent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass xx1800000102 Transparent plug Foundry Plus xx1800000101 Protec...

Page 393: ...elease tool is turned off 2 Connect the tool to the R2 MP5 connector 3 Release the brakes by pressing the button on the tool DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 4 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for m...

Page 394: ...0 IRB 5720 180 2 6 IRB 5720 155 2 6 LID M8x25 12 9 Gleitmo 603 Geomet 500 IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002204 See Performing a leak down test on page 188 Perform a leak down test 9 Disconnect the brake release tool 10 Connecting the axis 5 motor cables Note Action Put the motor cables in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 Refit the cable bracket w...

Page 395: ...amaged 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100002317 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 6 Continues on next page Product manual IRB 5720 395 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 5 Replacing the axis 5 motor Continued ...

Page 396: ... protection is available for variants IRB 5720 180 2 6 IRB 5720 155 2 6 LID Tightening torque 6 Nm Use locking liquid IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002495 IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002494 Continues on next page 396 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 5 Replacing the axis 5 motor Continued ...

Page 397: ... cover Note Action IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002627 Make sure that the cable harness is routed and secured as shown in the figure 1 IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002626 IRB 5720 180 2 6 IRB 5720 155 2 6 LID Continues on next page Product manual IRB 5720 397 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 5 Replacing the axis 5 motor Cont...

Page 398: ...crew M6x16 Stainless steel A2 70 Refit the wrist cover and secure with screws 3 Tightening torque 10 Nm xx2000000373 Concluding procedure Note Action See Filling oil into the axis 5 gearbox on page 173 Refill the gearbox with oil if drained 1 See Calibration on page 557 Re calibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 398 Product manual...

Page 399: ...via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC071374 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC070736 003 Motor unit Required service parts Note Article number Consumable Loctite 5800 3HAC041807 007 Flange sealant Continues on next page Product manual IRB 5720 399 3HAC079195 001 Revision A Copyright 2022 ABB All rig...

Page 400: ... 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC080346 001 IRB 5720 125 3 0 IRB 5720 90 3 0 LID Removal tool motor M10 Removal tool motor M8 Always use guide pins in pairs 3HAC15520 2 IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC080345 001 IRB 5720 125 3 0 IRB 5720 90 3 0 LID Guide pin M8x150 Guide pin M6x150 Used to rotate the motor pinion 3HAB7887 1 Rotation tool Delivered as a set of calibration tools Requ...

Page 401: ... it is possible to replace the motor without draining the oil from the axis 6 gearbox 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 Retrieving access to the wrist cabling Use this procedure to remove the wrist cover Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure...

Page 402: ... Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 402 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 6 Replacing the axis 6 motor Continued ...

Page 403: ...emove the connector bracket 3 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws that hold the cable bracket 5 Continues on next page Product manual IRB 5720 403 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 6 Replacing the axis 6 motor Continued ...

Page 404: ...113 Pull out the carrier from its position 7 xx1300000666 Pull out the axis 6 motor cables by holding the cables with one hand at the motor and the other at the carrier 8 Continues on next page 404 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 6 Replacing the axis 6 motor Continued ...

Page 405: ...motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk xx2000000377 Unscrew the motor attachment screws 2 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 3 Robot Motors Axis6 RemovalTool ArticleN umber Press the motor out of its position by using the remov...

Page 406: ...efit the motor Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove any old paint or flange sealant residues or other contamination from the contact surfaces on both the motor and the mating parts Tip Remove flange sealant residues with Loctite 7200 Then use Loctite 7063 for cleaning th...

Page 407: ...ightening torque protection filter 20 Nm xx1600000576 If the motor is a new spare part the evacuation hole protection filter must be replaced with a transparent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Refitting the axis 6 motor...

Page 408: ...ctly will cause serious injury Read and follow enclosed user instructions for the tool 3 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk CAUTION Whenever parting mating motor and gear box the gears may be damaged i...

Page 409: ...de pins 6 Hex socket head cap screw 4 pcs Secure the motor with its attachment screws 7 M8x30 12 9 Gleitmo 603 Geomet 500 IRB 5720 180 2 6 IRB 5720 155 2 6 LID M6x25 12 9 Gleitmo 603 Geomet 500 IRB 5720 125 3 0 IRB 5720 90 3 0 LID Tightening torque 10 Nm xx2000000377 See Performing a leak down test on page 188 Perform a leak down test 8 Continues on next page Product manual IRB 5720 409 3HAC079195...

Page 410: ...nto the wrist re cess and up into the axis 6 motor 2 xx1300001113 Push the carrier carefully into position 3 xx1300000485 Secure the carrier with the M4 screw Note The screw is located at the bottom of the carrier Tip The attachment screw securing the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 4 Continues on next page 410 Product manual...

Page 411: ... in accordance with the markings on the connectors Tightening torque 1 Nm Secure the power connector to the connect or bracket with a screw 7 Torx pan head screw M5x12 Stainless steel A2 70 xx2000000375 Refit the connector bracket with the at tached connectors 8 Continues on next page Product manual IRB 5720 411 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 6 Replac...

Page 412: ... Replace if damaged 3HAC074482 001 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC071520 001 xx2100001287 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 11 Continues on next page 412 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 6 Replacing the axis 6 motor Continued ...

Page 413: ...0 125 3 0 IRB 5720 90 3 0 LID xx2100002627 Make sure that the cable harness is routed and secured as shown in the figure 1 IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002626 IRB 5720 180 2 6 IRB 5720 155 2 6 LID Continues on next page Product manual IRB 5720 413 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 8 6 Replacing the axis 6 motor Continued ...

Page 414: ...teel A2 70 Refit the wrist cover and secure with screws 3 Tightening torque 10 Nm xx2000000373 Concluding procedure Note Action Axis Calibration is described in Calibrating with Axis Calibration method on page 565 Re calibrate the robot 1 General calibration information is included in section Calibration on page 557 DANGER Make sure all safety requirements are met when performing the first test ru...

Page 415: ...down the robot to floor standing and secure onto four support legs 2 If installed floor mounted Lift the robot and secure onto four support legs 3 Drain the axis 1 gearbox 4 Remove the cabling from the base 5 Remove the axis 1 motor 6 Remove the complete arm system complete robot excluding the base and axis 1 gearbox as an assembly 7 Replace the axis 1 gearbox Continues on next page Product manual...

Page 416: ...001 Grease Loctite 5800 3HAC041807 007 Flange sealant 3HAB3772 93 O ring Replace if damaged 3HAC072864 003 Graphite White 3HAC072864 005 ABB Orange Connection box cover FS180 with gasket Loctite 574 Flange sealant Sikaflex 521FC Protection type Foundry Plus Not required for option Inverted 3317 1 3HAC026759 001 Sealant grey Loctite 2400 3HAC041807 004 Locking liquid Loctite 5800 3HAC041807 007 Fla...

Page 417: ...AC16131 1 Lifting eye Adapter for lifting axis 1 gearbox 2 pcs 3HAC081565 001 Lifting adapter Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm Fender washer Lifting instruction 3HAC15880 2 enclosed 3HAC15556 1 Lifting accessory chain User instructions are enclosed with the tool 3HAC081310 001 Brake release tool 300 mm bits 1 2 3HAC12342 1 Bits extender 3HAC029090 001 B...

Page 418: ...ructions 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 Creating new values requires possibility to move the robot Read m...

Page 419: ...ue 550 Nm xx2100001114 For hole configuration see Hole configuration base on page 74 Lifting down the robot from inverted position Note Action Suitable screws lightly lubricated DANGER The robot must always be secured to the founda tion if any kind of repair or maintenance work is to be performed For some repair work support legs are required 1 M24 x 100 min 4 pcs For hole configuration see Hole c...

Page 420: ...Inverted 1 005 kg IRB 5720 125 3 0 985 kg Inverted 1 000 kg IRB 5720 155 2 6 LID 1 050 kg Inverted 1 070 kg IRB 5720 90 3 0 LID 1 050 kg Inverted 1 060 kg All lifting accessories used must be sized accord ingly 6 See user instructions enclosed with the fork lift accessory set Install the fork lift pockets to the robot DANGER Handling the tool incorrectly will cause serious injury Read and follow e...

Page 421: ... user instruc tions DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user in structions for the tool Lifting and turning tool 3HAC073537 001 Quantity 8 pcs xx1600002098 Remove the bolts that secure the robot to the foundation 9 Follow the user instructions en closed with the turning tool Rotate the robot to floor standing position 10 Attachment screws M24 x 1...

Page 422: ...he lifting accessories to the arm system This procedure is mainly meant for the floor mounted robot The inverted robot can use the already mounted lifting accessories Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Lifting eye 3HAC16131 1 Fit a lifting eye to the wrist 2 Continues on next page 422 Product manual IRB 5720 3HAC...

Page 423: ... 4 Lifting accessory set 3HAC15607 1 xx2100001165 Insert the lifting eyes to the fork lift attachment holes Use the lower attachment holes 5 xx2100001140 Attach the lifting accessories to the robot The back and front chains are only used as pre caution for any movement of the robot during the lift They do not need to be strained 6 Continues on next page Product manual IRB 5720 423 3HAC079195 001 R...

Page 424: ...ories used must be sized accordingly 1 xx2100001115 Unscrew the attachment screws from the foundation and lift away the robot to be able to fit the four support legs to the foundation 2 Support legs 3HAC15535 1 Secure the support legs to the foundation using the same holes as to secure the base 3 Tightening torque 550 Nm xx2100001114 Continues on next page 424 Product manual IRB 5720 3HAC079195 00...

Page 425: ...chieve the best stability of the complete arm system when it is resting by itself after it has been re moved Remove tools and other equipment fitted on the turning disc DressPack can stay fitted for the time being 3 xx2100001410 Hold the mechanical stop pin in a firm grip and remove it by unscrewing the attachment screw 4 See Floor mounted robot Draining the axis 1 gearbox on page 144 Begin draini...

Page 426: ...pletely at this point Disconnecting the axis 1 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 426 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 427: ...67 Disconnect the power cable connector by removing the attachment screw 3 Disconnect the signal cable connector 4 Continues on next page Product manual IRB 5720 427 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 428: ...Removing the axis 1 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 428 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 429: ...llow enclosed user instructions for the tool 2 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk Bits extender 3HAC12342 1 xx2100000503 Unscrew the attachment screws and washers Use a bits extender to reach the screw...

Page 430: ...if excess ive force is used 6 Removal tool motor M12 3HAC14631 1 Press the motor out of its position by using the removal tool in opposite holes of the motor 7 Always use removal tools in pairs xx2100002186 Use caution and lift the motor straight up to get the pinion parted from the gear 8 Disconnect the brake release tool 9 Continues on next page 430 Product manual IRB 5720 3HAC079195 001 Revisio...

Page 431: ...cal power hydraulic pressure and air pressure are turned off 1 xx2100000981 Remove the base cover 2 xx2100001109 Loosen the connectors R1 MP R1 SMB 3 Continues on next page Product manual IRB 5720 431 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 432: ...2100001108 Loosen the cable bracket from the frame by removing the screw 6 Removing the cable harness from the base Note Action Pull out the robot cable harness through the protection tube 1 Continues on next page 432 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 433: ...ame and install guide pins in the holes Tip Lubricate the guide pins with some grease to make the frame slide better 3 Guide pin M12x150 3HAC13056 2 Always use guide pins in pairs xx1400002169 Verify that all attachment screws are loosened from the frame 4 CAUTION The weight of the complete arm system is 700 769 kg depending on robot variant All lifting accessories must be sized accord ingly 5 Con...

Page 434: ...m on the floor 7 DANGER When the complete arm system is removed and resting by itself on the floor make sure it is resting completely stable before remov ing the lifting accessories Do not change the position of the axes from the position de scribed earlier 8 Continues on next page 434 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing...

Page 435: ...eters of space between the adapter and the surface of the gearbox This is done in order not to damage the surface of the gearbox which is a sealing surface 2 Lifting eye 3HAC16131 1 xx2100002817 CAUTION The weight of the gearbox is 97 kg All lifting accessories used must be sized accordingly 3 Continues on next page Product manual IRB 5720 435 3HAC079195 001 Revision A Copyright 2022 ABB All right...

Page 436: ...two persons working together one underneath the robot base making sure that the bit is being fitted into the screw head holes all the way until they reach the bottom one using the torque wrench loosen ing the screws from beside the base 5 Continues on next page 436 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox C...

Page 437: ...6 Lift away the gearbox WARNING Approximately 0 5 l of oil residues will drip out during lifting of the gearbox Make sure that protective gear like goggles and gloves are always worn WARNING Used oil is hazardous material and must be disposed of in a safe way See Decommission ing on page 587 for more information 8 Continues on next page Product manual IRB 5720 437 3HAC079195 001 Revision A Copyrig...

Page 438: ...e base is 170 kg All lifting accessories used must be sized accordingly 1 Support legs 3HAC15535 1 If not already done fit and secure the four support legs to the foundation Then lift up and secure the base on top of the legs 2 Tightening torque 550 Nm xx2100001135 xx1700000567 Wipe the contact surfaces between gearbox and base clean from any contamination 3 Continues on next page 438 Product manu...

Page 439: ...apter 3HAC081565 001 Fit the lifting accessories in opposite holes in the gearbox CAUTION Leave a couple of millimeters of space between the lug and the surface of the gear box This is done in order not to damage the surface of the gearbox which is a sealing surface 6 Lifting eye 3HAC16131 1 xx2100002819 CAUTION The weight of the gearbox is 97 kg All lifting accessories used must be sized accordin...

Page 440: ...rbox 9 O ring 3HAC061327 033 32x4 Clean the new o rings lubricate them with some grease and fit them in their grooves in the gearbox 10 Grease Shell Gadus S2 3HAC042536 001 xx2000000413 Not required for option Inverted 3317 1 Continues on next page 440 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 441: ...urface inside the frame with grease 12 Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended dry ing time is 24h xx2100001117 Apply rust preventive to the gearbox surface shown in the figures 13 Continues on next page Product manual IRB 5720 441 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 442: ... gearbox as shown in the figure 14 Guide pin M16x200 3HAC13120 3 Fit guide pins in opposite holes in the gear box Tip Lubricate the guide pins with some grease to make the gearbox slide better 15 Always use guide pins in pairs xx2100002821 Continues on next page 442 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox ...

Page 443: ...revent the screws from falling out Note Do not use the new o ring 1 If the attachment screws are not fitted like this at this point they must be fitted by rotating axis 1 to get access at the mech anical stop pin location one at a time xx1400002176 xx2100001167 Verify that the locating pin in the gearbox will match the hole in the base 2 Continues on next page Product manual IRB 5720 443 3HAC07919...

Page 444: ...attachment screws that secure the gearbox to the base from underneath 5 Remove the guide pins and fit the two remain ing screws 6 Tightening torque 300 Nm Secure the attachment screws Tip This procedure is best performed by two persons working together one underneath the robot base making sure that the bit is being fitted into the screw head holes all the way until they reach the bottom one using ...

Page 445: ...loor mounted robot 1 Foundry Plus Cut the flange sealant at the sealing ring protec tion tube Continues on next page Product manual IRB 5720 445 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 446: ...t tachment screws 1 xx2100002493 Option Inverted 3317 1 Remove the adapter by removing the attachment screws 2 Removing the cassette sealing Note Action xx2100002309 Remove the cassette sealing by knocking it down through the frame 1 Continues on next page 446 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Contin...

Page 447: ... the gearbox 3 Guide pin M12x150 3HAC13056 2 2 pcs Apply guide pins in the guide pin holes in the gearbox Tip Lubricate the guide pins with some grease to make the frame slide better 4 Always use guide pins in pairs xx1700000329 Refitting the arm system Note Action CAUTION The weight of the complete arm system is 700 769 kg depending on robot variant All lifting accessories must be sized accord in...

Page 448: ...e pins until it is possible to insert the attachment screws manually CAUTION Do not lower the arm system completely at this stage The attachment screws must be fitted in two steps If not the complete arm system will risk resting on the attachment screws in the wrong position 7 Hex socket head cap screw M12x60 12 9 Gleitmo 603 Geomet 500 16 pcs Fit the attachment screws manually as far as possible ...

Page 449: ...maining attachment screw can be secured 12 xx1700000320 Remove the guide pins and refit the two plastic protection plugs 13 xx1700000321 Tightening torque 10 Nm Refit the back plate and secure with two screws 14 Torx pan head screw M6x16 Stainless steel A2 70 2 pcs xx2000000411 Remove the lifting accessories 15 Continues on next page Product manual IRB 5720 449 3HAC079195 001 Revision A Copyright ...

Page 450: ...om the contact surfaces for the sealing in the frame 1 Lubricate the mounting surfaces in the frame with grease 2 Replacement tool for cassette sealing 3HAC079880 001 xx2100001188 Fit the first part of the mounting tool to the frame 3 xx2100001189 Fit the cassette sealing on the tool with the plain side facing upwards groove down wards 4 Continues on next page 450 Product manual IRB 5720 3HAC07919...

Page 451: ...ng has reached the bottom all the way around Remove the mounting tool 7 xx2100001193 Verify that the cassette sealing is fitted evenly by measuring the distance A between the painted edge of the frame and down to the sealing at four 4 locations The measurement is approximately 16 mm 8 Continues on next page Product manual IRB 5720 451 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserve...

Page 452: ...te sealing as shown in the figure 9 xx2100001172 Sealant grey 3HAC026759 001 Only for floor mounted robot with protec tion type Foundry Plus 10 Sikaflex 521FC Apply sealant to the mounting surface for the sealing ring Protection type Foundry Plus Not required for option Inverted 3317 1 xx2100001173 Continues on next page 452 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All ...

Page 453: ... Action xx1700001374 Check the protection tube for damages Especially inspect the surface for the sealing ring not available for option Inverted 3317 1 Replace if damaged 1 Option Inverted 3317 1 xx2100001168 Wipe the surfaces of the protection tube clean from any contamination 2 Continues on next page Product manual IRB 5720 453 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 R...

Page 454: ...x pan head screw M6x16 A4 80 2 pcs xx2100002493 Option Inverted 3317 1 Refit the adapter with the attachment screws 4 Torx pan head screw M6x16 A4 80 4 pcs Option Inverted 3317 1 Refit the protection tube with the attachment screws 5 Locking liquid 3HAC041807 004 Loctite 2400 Apply locking liquid on the screws Tightening torque 10 Nm xx2100002492 Continues on next page 454 Product manual IRB 5720 ...

Page 455: ... flange sealant residues with Loctite 7200 Then use Loctite 7063 for cleaning the mating surface 2 Flange sealant 3HAC041807 007 Loctite 5800 xx2100000520 Apply a continuous bead of flange sealant 1 2 mm wide inside of the groove on the motor con tact surface Note The purpose of the groove is to catch excess sealant No o ring is used 3 Continues on next page Product manual IRB 5720 455 3HAC079195 ...

Page 456: ...rent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Floor mounted robot Refitting the axis 1 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs xx2100001194 Continues on n...

Page 457: ...ing the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 4 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the specified brake release tool to eliminate the risk CAUTION Whenever parting mating motor and gearbox the gear...

Page 458: ...ing torque 50 Nm xx2100000503 Disconnect the brake release tool 8 See Performing a leak down test on page 188 Perform a leak down test if not already done 9 Refilling oil in the gearbox Note Action See Changing the oil in axis 1 gearbox on page 143 Refill oil in the gearbox Option Inverted 3317 1 1 Because of the risk of getting air bubbles into axis 1 gear in inverted position when filling oil it...

Page 459: ...run on the correct side of the R1 MP1 see the figure 2 Make sure that the markings on the cables are facing the base cover when connected 3 Screw dimension for R1 MP M6x25 A2 70 Connect connectors R1 MP and R1 SMB 4 Tightening torque for R1 MP 10 Nm Tightening torque for R1 SMB 10 Nm xx2100001109 Continues on next page Product manual IRB 5720 459 3HAC079195 001 Revision A Copyright 2022 ABB All ri...

Page 460: ...rque 10 Nm xx2100000982 Torx pan head screw M6x16 Stainless steel A2 70 Refit the base cover 6 Tightening torque 10 Nm xx2100000981 Continues on next page 460 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 461: ...fit the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Tightening torque 1 Nm xx2100000667 Secure the power connector with a screw 4 Continues on next page Product manual IRB 5720 461 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 462: ...BB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Axis 5 Connection box cover with gasket gasket not needed for protection type Standard IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will ...

Page 463: ...remaining cable brackets Note Action Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended dry ing time is 24h xx2100001139 Protection type Foundry Plus Apply rust preventive on the surfaces shown in the figure on stop pin and in the hole as shown in the figure 1 Continues on next page Product manual IRB 5720 463 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair...

Page 464: ...htening torque 24 Nm xx2100001410 xx2100001108 Refit the cable bracket on the frame 3 Refitting covers for Foundry Plus and floor mounted robots Note Action Torx pan head screw M6x16 Stainless steel A2 70 6 pcs xx2100000979 Protection type Foundry Plus Refit the axis 1 cable protection plate with the attachment screws 1 Continues on next page 464 Product manual IRB 5720 3HAC079195 001 Revision A C...

Page 465: ...D 1 050 kg Inverted 1 060 kg All lifting accessories used must be sized accordingly 1 Lifting accessory set 3HAC15607 1 xx2100002226 Attach the lifting accessories to the robot 2 Stretch the lifting accessories enough to se cure the robot but without taking the full weight of the robot 3 Continues on next page Product manual IRB 5720 465 3HAC079195 001 Revision A Copyright 2022 ABB All rights rese...

Page 466: ... inverted robot to the foundation Use this procedure to orient and secure the robot inverted Note Action See user instructions enclosed with the fork lift accessory set Install the fork lift pockets to the robot DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 1 Fork lift accessory set 3HAC058825 001 Continues on next page 466 P...

Page 467: ...e to its installation location 4 Lifting and turning tool 3HAC073537 001 Rotate the robot into inverted position using the turning tool or using a fork lift truck with a rotator attachment DANGER Make sure that there is enough space underneath the robot See user instructions for the turning tool 5 See user instructions enclosed with the turning tool Guide the robot using two attachment screws whil...

Page 468: ...he base 9 Concluding procedure Note Action See Calibration on page 557 Calibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 468 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 1 Replacing the axis 1 gearbox Continued ...

Page 469: ...nearby the robot There should be enough space to place foam boards pallets or similar protective material nearby the robot If needed run axis 1 into a position that gives the required space The figure shows an example DANGER The base shall be fitted to the foundation when performing this procedure xx2000000441 Continues on next page Product manual IRB 5720 469 3HAC079195 001 Revision A Copyright 2...

Page 470: ...his is a brief summary of the replacement procedure containing the major actions to be performed 1 If installed in an inverted position option 3317 1 Lift down the robot to floor standing and secure to the foundation 2 Drain the axis 2 gearbox 3 Loosen the cabling brackets inside the lower arm and on the frame 4 Remove the upper and lower arm mounted together as an assembly 5 Remove the axis 2 mot...

Page 471: ...ngth 1 5 m Roundsling 1 5 m Length 1 m Roundsling 1 m User instructions are enclosed with the tool 3HAC081310 001 Brake release tool 300 mm bits 1 2 3HAC12342 1 Bits extender Used to push out the motor if necessary Always use removal tools in pairs 3HAC14631 1 Removal tool motor M12 Lifting instruction 3HAC15640 2 enclosed 3HAC15534 1 Lifting accessory motor Always use guide pins in pairs 3HAC1552...

Page 472: ...sealant 3HAC061327 067 O ring Replace if damaged 3HAC072864 003 Graphite White 3HAC072864 005 ABB Orange Connection box cover FS180 with gasket See Type of lubrication in gear boxes on page 141 Lubricating oil Used on oil plug Always replace when refitting oil plug 3HACxxx O ring Deciding calibration routine Decide which calibration routine to be used based on the information in the table Dependin...

Page 473: ...ation Remove all external cable packages DressPack and tools from the robot Removing the gearbox Use these procedures to remove the gearbox CAUTION When performing these procedures the cable harness will still be fitted or partly fitted to the robot Use extreme caution not to cause any damage to the cable harness Lifting down the robot from inverted position Note Action Suitable screws lightly lub...

Page 474: ...Inverted 1 005 kg IRB 5720 125 3 0 985 kg Inverted 1 000 kg IRB 5720 155 2 6 LID 1 050 kg Inverted 1 070 kg IRB 5720 90 3 0 LID 1 050 kg Inverted 1 060 kg All lifting accessories used must be sized accord ingly 6 See user instructions enclosed with the fork lift accessory set Install the fork lift pockets to the robot DANGER Handling the tool incorrectly will cause serious injury Read and follow e...

Page 475: ... Read and follow enclosed user in structions for the tool Lifting and turning tool 3HAC073537 001 Quantity 8 pcs xx1600002098 Remove the bolts that secure the robot to the foundation 9 Follow the user instructions en closed with the turning tool Rotate the robot to floor standing position 10 Attachment screws M24 x 100 min 4 pcs required to perform service Lower and secure the robot to the floor O...

Page 476: ...draining the gearbox 4 Attaching lifting accessories to the lower and upper arm Note Action CAUTION The weight of the complete upper and lower arm together is IRB 5720 180 2 6 IRB 5720 155 2 6 LID 440 kg IRB 5720 125 3 0 IRB 5720 90 3 0 LID 390 kg All lifting accessories used must be sized accord ingly 1 Lifting eye 3HAC16131 1 xx2100001413 Fit a lifting eye to the wrist 2 Continues on next page 4...

Page 477: ...is done to secure the roundsling from gliding when lifting 4 Roundsling 1 5 m Length 1 5 m Run a roundsling around the lower arm 5 IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100001415 Attach the roundsling to the shackle on the wrist 6 IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100001469 Continues on next page Product manual IRB 5720 477 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved ...

Page 478: ...ifting eye in the arm house with a fender washer underneath 9 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx2100002146 Lifting accessory chain 3HAC15556 1 Attach the Lifting accessory chain to an over head crane or similar then to the lifting eye in the arm house and to a roundsling run through the wrist 10 Roundsling 1 m Length 1 m xx2000000452 Cont...

Page 479: ...ER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx2100000596 Remove the motor cover by removing the screws 2 xx2100000667 Disconnect the power cable connector by removing the attachment screw 3 Disconnect the signal cable connector 4 Continues on next page Product manual IRB 5720 479 3HAC079195 001 Revision A Copyright 2022 ABB All rights re...

Page 480: ...earbox is completely drained 1 DANGER When releasing the holding brakes of the motor the lower arm will be movable and may fall down if not secured Verify that the lower arm is secured as previously de scribed before continuing 2 Continues on next page 480 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 481: ...dslings are stretched by raising the overhead crane before releas ing the brakes 3 User instructions are enclosed with the tool xx2100000666 DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake...

Page 482: ...ut of its position by using the removal tool in opposite holes of the motor 7 Used to push out the motor if necessary Always use removal tools in pairs CAUTION The weight of the motor is 25 kg All lifting accessories used must be sized accordingly 8 xx2000000457 Carefully lift the motor out on the guide pins in order to get the pinion away from the gear and let it rest on the guide pins 9 Disconne...

Page 483: ...he cable harness and DressPack kept installed in the base and in the frame Note Keeping the cable harness and DressPack fitted on the robot during gearbox replacement is only a recommendation If it is not possible to put the lower and upper arm close enough to the robot the cable harness and DressPack in the base and in the frame must be removed first Note Action xx2100001104 Unscrew the attachmen...

Page 484: ...de pin M16x150 Guide pin M16x200 3HAC13120 2 3HAC13120 3 Remove two attachment screws in opposite holes and replace them with guide pins Tip Use different lengths on the guide pins to simplify guidance 1 Always use guide pins in pairs xx2100002410 Tip Lubricate the guide pins with some grease to make the lower arm slide better Continues on next page 484 Product manual IRB 5720 3HAC079195 001 Revis...

Page 485: ... position that gives the required space Note Keeping the cable harness and DressPack fitted on the robot during gearbox replace ment is only a recommendation If it is not possible to put the lower and upper arm close enough to the robot the cable har ness and DressPack in the base and in the frame must be removed first 1 CAUTION The weight of the complete upper and lower arm together is IRB 5720 1...

Page 486: ...ther Let the cabling run in the lower arm Make sure not to stretch any cabling CAUTION Use extreme caution when lifting away the arms The cable harness is still partly con nected 3 Continues on next page 486 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 487: ...ION Use stoppers on the guide pins 1 Always use guide pins in pairs xx2100002412 Tip Use different lengths on the guide pins to simplify guidance Tip Lubricate the guide pins with some grease to make the lower arm slide better xx2100002413 Leave one of the upper attachment screws and remove the rest The remaining screw is used to prevent the gearbox from falling down 2 CAUTION The weight of the ge...

Page 488: ...s on the guide pins 6 Attach the lifting accessory to the gearbox 7 Remove the gearbox 8 Refitting the gearbox Use these procedures to refit the gearbox Preparations before refitting the axis 2 gearbox Note Action CAUTION The weight of the gearbox is 97 kg All lifting accessories used must be sized accordingly 1 Continues on next page 488 Product manual IRB 5720 3HAC079195 001 Revision A Copyright...

Page 489: ...lean the contact surfaces on both the gearbox and the frame from any con tamination Note Also wipe clean the o ring groove 4 O ring 3HAC061327 067 xx2100001132 Check the o ring Replace if damaged 5 Continues on next page Product manual IRB 5720 489 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 490: ...5 Apply rust preventive to the gearbox sur face shown in the figures 7 Refitting the axis 2 gearbox Use this procedure to refit the gearbox Note Action CAUTION The weight of the gearbox is 97 kg All lifting accessories used must be sized accordingly 1 Continues on next page 490 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 2 Replacing the axi...

Page 491: ...e grease to make the lower arm slide better xx2100002414 Lift the gearbox and let it rest on the guide pins CAUTION Use stoppers on the guide pins 3 Remove the lifting accessory DANGER There is a risk that the gearbox may glide out and fall down if it is too far out to on the guide pins 4 Continues on next page Product manual IRB 5720 491 3HAC079195 001 Revision A Copyright 2022 ABB All rights res...

Page 492: ...er and upper arm Use this procedure to lift back and refit the lower and upper arm mounted together Note Action Guide pin M16x150 Guide pin M16x200 3HAC13120 2 3HAC13120 3 Fit two guide pins in opposite holes in the axis 2 gearbox Tip Use different lengths on the guide pins to simplify guidance 1 Always use guide pins in pairs xx2100002417 Tip Lubricate the guide pins with some grease to make the ...

Page 493: ...ogether Make sure not to stretch any of the cables that the arm package is level when lifted 4 Adjustment tool for gear 3HAC080331 001 Guide the lower arm onto the guide pins and check if the hole pattern between the gearbox and the lower arm matches 5 If the hole pattern does not match use the adjustment tool in the axis 2 gear and ro tate until a matching hole pattern is achieved xx1300000819 Co...

Page 494: ... 603 Geomet 500 xx2100002410 Remove the two guide pins and replace with the remaining attachment screws and washers 8 Tightening torque see standard torque in Screw joints on page 592 Tighten the attachment screws 9 Remove the lifting accessories 10 Continues on next page 494 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis ...

Page 495: ... flange sealant residues with Loctite 7200 Then use Loctite 7063 for cleaning the mating surface 2 Flange sealant 3HAC041807 007 Loctite 5800 xx2100000520 Apply a continuous bead of flange sealant 1 2 mm wide inside of the groove on the motor con tact surface Note The purpose of the groove is to catch excess sealant No o ring is used 3 Continues on next page Product manual IRB 5720 495 3HAC079195 ...

Page 496: ... a transparent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Refitting the axis 2 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs xx2100000593 Continues on next page 4...

Page 497: ...accordingly 2 Lifting accessory motor 3HAC15534 1 Apply the lifting accessory 3 Lifting accessory chain 3HAC15556 1 xx2100000594 Continues on next page Product manual IRB 5720 497 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 498: ...as close as possible to its final position without pushing the motor pinion into the gear 5 xx2000000457 Remove the lifting accessory and allow the motor to rest on the guide pins 6 Continues on next page 498 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 499: ... mating motor and gear box the gears may be damaged if excess ive force is used 8 Rotation tool 3HAB7887 1 Apply the rotation tool 9 Use caution and fit the motor in its final position while at the same time rotating the motor pinion slightly using the rotation tool Make sure that the motor pinion is properly mated to the gear of the gearbox Make sure that the motor pinion does not get damaged Mak...

Page 500: ... attachment screws 11 Tightening torque 50 Nm Tighten the screws 12 Disconnect the brake release tool 13 See Performing a leak down test on page 188 Perform a leak down test 14 Continues on next page 500 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 501: ...fit the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Tightening torque 1 Nm xx2100000667 Secure the power connector with a screw 4 Continues on next page Product manual IRB 5720 501 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 2 Replacing the axis 2 gearbox Continued ...

Page 502: ...BB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Axis 5 Connection box cover with gasket gasket not needed for protection type Standard IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will ...

Page 503: ...he cabling Use this procedure to refit the cabling Note Action Use caution and push the cable harness into the lower arm 1 xx2100001104 Refit the axis 2 lower arm metal clamp and the axis 3 lower arm metal clamp located on the inside of the lower arm 2 Continues on next page Product manual IRB 5720 503 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 2 Replacing the ax...

Page 504: ...uck into the fork lift pockets as far as possible 2 Raise the forks of the fork lift truck to make sure that the weight of the robot rests on the forks Tip Two M16 screws can be fitted to the fork lift pockets to press the forks against the pockets and make the lift more stable See user instructions enclosed with the turning tool Lifting and turning with the turning tool and overhead crane 1 Insta...

Page 505: ...ricate screws before assembly 7 Suitable washer 4 mm flat washer Screw tightening yield point utiliza tion factor v according to VDI2230 90 v 0 9 Tightening torque CAUTION If high stress on screws are suspected replace used screws with new ones 550 Nm screws lubricated with Molykote 1000 600 725 Nm typical 650 Nm screws none or lightly lubricated Tighten bolts in a crosswise pattern to ensure that...

Page 506: ...o pallets in a row For inverted manipulators the cable harness and DressPack cable package must be removed from the upper arm Location of the gearbox The gearbox is located as shown in the figure xx2100000484 Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 5720 via myABB Business Portal www abb com myABB Continu...

Page 507: ...1310 001 Brake release tool Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 For lifting the gearbox 3HAC081585 001 Lifting accessory for gear Used to push out the gearbox if necessary Screws M8x75 fully threaded Used to rotate the gear for matching hole pattern with frame 3HAC080331 001 Adjustment tool for gear Delivered as a set of calibration tools Required if Axis Calibration is th...

Page 508: ...re 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 Reference calibration routine on page 566 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibr...

Page 509: ...ies to the upper arm 170 shown in figure Axis 2 47 Axis 3 135 upper arm horizontal Axis 4 0 Axis 5 90 Axis 6 0 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 5 Choose to remove the cabling from the upper arm if any of following circum stances is true There is not enough free space to put down the upper a...

Page 510: ...8 If cabling needs to be removed Retrieving access to the wrist cabling Use this procedure to remove the wrist cover Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 510 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Co...

Page 511: ...6 motor cables 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 5720 511 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 512: ...move the connector bracket 3 Disconnect the motor cables 4 xx1300000484 Unscrew the attachment screws that hold the cable bracket 5 Continues on next page 512 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 513: ...lding the cables with one hand at the motor and the other at the carrier 8 If cabling needs to be removed Disconnecting the axis 5 motor cables 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 5720 513 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Repl...

Page 514: ...0002625 IRB 5720 180 2 6 IRB 5720 155 2 6 LID xx2100002495 Remove the motor cover by removing the screws 3 IRB 5720 125 3 0 IRB 5720 90 3 0 LID xx2100002494 Continues on next page 514 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 515: ...Pack Remove the cover Note Use caution not to damage the gasket 1 DressPack xx2100002679 xx1300000668 Tip Use tape and tie the axis 5 and axis 6 connectors and carrier into a bundle if not already done This is done to facilitate the removal and to avoid damaging the parts This will also make it easier to run the cable harness through the inside of the upper arm 2 Continues on next page Product man...

Page 516: ...axis 4 metal clamp inside the arm tube Note The screw is reached from outside the up per arm 4 xx1700000339 xx2100002154 Remove the arm house metal clamp 5 Continues on next page 516 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 517: ...rist xx1300000746 Person 1 working at side hole xx2000000416 Remove the cable harness out of the arm tube at the back of the upper arm Tip This step is best performed by two persons working together Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Move the cable harness out of the arm tube 7 ...

Page 518: ... washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx2100002146 Lifting accessory chain 3HAC15556 1 Attach the upper arm lifting accessory chain to the lifting eye to an overhead crane or similar and then to a roundsling in the wrist 3 Roundsling 1 5 m xx2100002145 Approximate length of the chain a 1 200 mm b 1 420 mm Raise the lifting accessories to take the wei...

Page 519: ... 5 Disconnecting the axis 3 and axis 4 motor cables 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 5720 519 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 520: ...67 Disconnect the power cable connector by removing the attachment screw 3 Disconnect the signal cable connector 4 Continues on next page 520 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 521: ... gearbox is completely drained 1 DANGER When releasing the holding brakes of the motor the upper arm will be movable and falls down if not secured Verify that the upper arm is secured as previously de scribed before continuing 2 Continues on next page Product manual IRB 5720 521 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 522: ...ause serious injury Read and follow enclosed user instructions for the tool WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk Bits extender 3HAC12342 1 xx2100002153 Remove two opposite attachment screws Use a bits extender in order to reach the screws 4 Guide pin M10x150 3H...

Page 523: ...ing the cable brackets This procedure is valid if wanting to keep the cabling installed in the upper arm when removing the upper arm from the robot If this is not possible due to lack of space where to put the upper arm the cable harness must be removed from the upper arm see Removing the cable harness upper arm and wrist on page 262 Use this procedure to loosen required cable brackets of the robo...

Page 524: ... can stay fitted if the distance between the axis 3 rotation centre and the floor does not exceed 2 1 m If the distance exceeds 2 1 m the cabling in the upper arm and the wrist must be removed Removal of the cabling in the upper arm and wrist is described in Removing the cable harness upper arm and wrist on page 262 Continues on next page 524 Product manual IRB 5720 3HAC079195 001 Revision A Copyr...

Page 525: ...3 Leave one of the remaining attachment screws fitted remove the other screws 2 Removing the upper arm Note Action xx1400002197 Note Make sure the lift is done completely leveled In case of necessary adjustments use the shortening loops on the lifting ac cessory chain and make sure to place the chain the right way through the loops 1 Continues on next page Product manual IRB 5720 525 3HAC079195 00...

Page 526: ... robot in order not to cause any damage to the cable harness 3 xx1300000553 This step is only valid when the upper arm is removed due to replacement of the axis 3 gearbox Place pieces of wood or similar under arm house and wrist Lower the upper arm and let the upper arm rest as shown in the fig ure This is done in order to keep the axis 3 gearbox in a vertical position and to get the best position...

Page 527: ...450 xx2100002447 Remove all but one of the remaining attach ment screws and washers 2 Screws M8x75 fully threaded Used to push out the gearbox if necessary xx2100001224 Fit two fully threaded screws in the press out holes 3 Note There will be some oil spill when the gear box is removed Put some oil absorbent cloth or paper below the gearbox 4 Continues on next page Product manual IRB 5720 527 3HAC...

Page 528: ...r 3HAC081585 001 xx2100002460 Apply the lifting accessory to the gearbox 7 With the gearbox attached to the lifting ac cessory remove the gearbox by letting it slide out on the guide pins 8 Remove the gearbox 9 Refitting the gearbox Use these procedures to refit the axis 3 gearbox Preparations before refitting the axis 3 gearbox Note Action CAUTION The weight of the gearbox is 45 kg All lifting ac...

Page 529: ... its side 3 Wipe clean the contact surfaces of both the gearbox and the upper arm from any con tamination 4 O ring 3HAC061327 063 xx2100001237 Check the o ring Replace if damaged 5 Continues on next page Product manual IRB 5720 529 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 530: ... Always use guide pins in pairs xx2100002462 Tip Lubricate the guide pins with some grease to make the lower arm slide better xx2100002460 Lift the gearbox and let it rest on the guide pins 2 Remove the lifting accessory DANGER There is a risk that the gearbox may glide out and fall down if it is too far out to on the guide pins 3 Continues on next page 530 Product manual IRB 5720 3HAC079195 001 R...

Page 531: ...age 592 Tighten the attachment screws 6 Preparations before refitting the upper arm Note Action Wipe clean all contact surfaces 1 Guide pin M12x150 3HAC13056 2 Fit two guide pins in opposite M12 holes in the axis 3 gearbox Tip Lubricate the guide pins with some grease to make the upper arm slide better 2 Always use guide pins in pairs xx2100002445 Continues on next page Product manual IRB 5720 531...

Page 532: ...ready fitted 2 Lift the upper arm to mounting position 3 Adjustment tool for gear 3HAC080331 001 xx2000000395 Use the adjustment tool to rotate the axis 3 gearbox and find the correct position for the guide pins in the lower arm 4 Hex socket head cap screw M12x40 12 9 Gleitmo 603 Geomet 500 26 pcs Insert all but two of the screws and wash ers 5 Washer Steel 13x19x1 5 24 pcs xx2100002443 Continues ...

Page 533: ... other contamination from the contact surfaces on both the motor and the mating parts Tip Remove flange sealant residues with Loctite 7200 Then use Loctite 7063 for cleaning the mating surface 2 Flange sealant 3HAC041807 007 Loctite 5800 xx2100000520 Apply a continuous bead of flange sealant 1 2 mm wide inside of the groove on the motor con tact surface Note The purpose of the groove is to catch e...

Page 534: ... spare part delivery Remove the protection filter and install the transparent plug sight glass xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Refitting the axis 3 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs xx2100002151 CAUTION The weight of the motor is 13 kg All lifting accessories used mus...

Page 535: ...0000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 5 Rotation tool 3HAB7887 1 Apply the rotation tool 6 Use caution and fit the motor in its final position while a...

Page 536: ...own test on page 188 Perform a leak down test 11 Refitting cable brackets This procedure is valid if the cabling has been kept installed in the upper arm when removing the upper arm from the robot If the cable harness in the upper arm instead has been removed completely see Refitting the cable harness upper arm and wrist on page 291 Use this procedure to refit the cable brackets Note Action Remove...

Page 537: ...screw M6x16 Stainless steel A2 70 Refit the metal clamp on top of the arm house 4 Tightening torque 10 Nm xx2100001285 Torx pan head screw M6x16 Stainless steel A2 70 Refit the metal clamp beneath the arm house 5 Tightening torque 10 Nm xx2100002154 Continues on next page Product manual IRB 5720 537 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis ...

Page 538: ...t the motor cables in place in the open ing 1 Torx pan head screw M3x12 Stainless steel A2 70 xx2100000598 Refit the cable bracket with the screws 2 Connect the motor cables 3 Connect in accordance with the markings on the connectors Continues on next page 538 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Contin...

Page 539: ... 1 Nm xx2100000667 Secure the power connector with a screw 4 Continues on next page Product manual IRB 5720 539 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 540: ...BB Orange Axis 4 Connection box cover FS130 with gasket 3HAC072863 003 Graphite White 3HAC072863 005 ABB Orange Axis 5 Connection box cover with gasket gasket not needed for protection type Standard IRB 5720 180 2 6 IRB 5720 155 2 6 LID 3HAC072863 003 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC072862 003 xx2100000600 CAUTION When fitting the motor cover make sure that none of the cables inside will ...

Page 541: ...x pan head screw M6x16 Stainless steel A2 70 If cabling has been removed Refit the metal clamp on top of the arm house 1 Tightening torque 10 Nm xx2100001285 Cable ties xx2000000415 If cabling has been removed Secure the cable harness to the arm house eyelet with a cable tie 2 Continues on next page Product manual IRB 5720 541 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repa...

Page 542: ...box 3 See Calibration on page 557 Calibrate the robot 4 DANGER Make sure all safety requirements are met when performing the first test run 5 542 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 3 Replacing the axis 3 gearbox Continued ...

Page 543: ...RB 5720 155 2 6 LID 3HAC072405 003 Graphite White 3HAC072405 004 ABB Orange IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC074187 003 Graphite White 3HAC074187 004 ABB Orange Gearbox Required service parts Note Article number Consumable P 80 Emulsion IFC 3HAC074427 001 P 80 rubber lubration gel Loctite 5800 3HAC041807 007 Flange sealant Mercasol 3110 Waxcoat Recom mended drying time is 24h 3HAC034903 00...

Page 544: ...e required prior to beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibrat...

Page 545: ...e axis 6 gearbox on page 176 Drain the gearbox 3 Remove all equipment fitted on the turning disc 4 Floor mounted robot 5 Jog the robot into position Axis 1 no significance Axis 2 suitable working position to replace axis 6 gearbox for example 25 Axis 3 suitable working position to replace axis 6 gearbox for example 20 Axis 4 0 Axis 5 55 Axis 6 0 Option Inverted 3317 1 6 Jog the robot into position...

Page 546: ... and washers that se cure the turning disc 1 IRB 5720 155 2 6 LID IRB 5720 90 3 0 LID TBD xx2100002168 Remove the turning disc 2 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 546 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reser...

Page 547: ...ove the motor cover 2 xx2000000375 Remove the connector bracket 3 Disconnect the motor cables 4 Continues on next page Product manual IRB 5720 547 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 4 Replacing the axis 6 gearbox Continued ...

Page 548: ...tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool 1 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk Continues on next page 548 Product manual IRB 5720 3HAC079195 001...

Page 549: ...2228 Fit guide pins 3 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 4 Continues on next page Product manual IRB 5720 549 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 4 Replacing the axis 6 gearbox Continued ...

Page 550: ... DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Wipe clean the contact surfaces of both gearbox and wrist from any contamination 2 O ring 3HAC061327 070 xx2100002258 Check the o ring Replace if damaged 3 Continues on next page 550 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 4 Rep...

Page 551: ... with grease 4 Flange sealant 3HAC041807 007 xx2100002233 Protection type Foundry Plus Apply flange sealant on the surface shown in the figure 5 Continues on next page Product manual IRB 5720 551 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 4 Replacing the axis 6 gearbox Continued ...

Page 552: ...r the tool 6 User instructions are enclosed with the tool xx2100000666 WARNING Electrical damage to the motor may occur if 24V is supplied to the motor connector for more than 30 seconds Use the spe cified brake release tool to eliminate the risk Refitting the axis 6 gearbox Note Action CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 1 Contin...

Page 553: ...002227 Disconnect the brake release tool 4 See Performing a leak down test on page 188 Perform a leak down test 5 Jog axis 5 to horizontal position 6 See Filling oil into the axis 6 gearbox on page 178 Refill oil in the gearbox 7 Connecting the axis 6 motor cables Note Action Connect the motor cables 1 Connect in accordance with the markings on the connectors Tightening torque 1 Nm Secure the powe...

Page 554: ...s shown in the figure 4 Gasket tilt housing cover Inspect the gasket 5 IRB 5720 180 2 6 IRB 5720 155 2 6 LID Replace if damaged 3HAC074482 001 IRB 5720 125 3 0 IRB 5720 90 3 0 LID 3HAC071520 001 xx2100001287 Continues on next page 554 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 4 Replacing the axis 6 gearbox Continued ...

Page 555: ... Refitting the turning disc Note Action Wipe clean the contact surfaces 1 Rust preventive 3HAC034903 001 Mercasol 3110 Waxcoat Recom mended drying time is 24h xx2100002232 Protection type Foundry Plus Apply rust preventive to the surface shown in the figure 2 Continues on next page Product manual IRB 5720 555 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 5 Repair 5 9 4 Replacing...

Page 556: ...IRB 5720 180 2 6 IRB 5720 155 2 6 LID 9 pcs IRB 5720 125 3 0 IRB 5720 90 3 0 LID Steel 8 4x13x1 5 Tightening torque see standard torque in Screw joints on page592 IRB 5720 180 2 6 IRB 5720 125 3 0 xx2100002167 IRB 5720 155 2 6 LID IRB 5720 90 3 0 LID TBD Concluding procedure Note Action See Calibration on page 557 Calibrate the robot 1 DANGER Make sure all safety requirements are met when performi...

Page 557: ... generic 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 ...

Page 558: ...ccuracy 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 5720 It is the recommended method in...

Page 559: ...s 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 liste...

Page 560: ... page 563 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 whe...

Page 561: ...ition for axes Introduction This section shows the position of the synchronization marks and the synchronization position for each axis Product manual IRB 5720 561 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 6 Calibration 6 2 1 Synchronization marks and synchronization position for axes ...

Page 562: ... in gears and so on Positive directions are shown in the graphic below Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions xx2100002527 562 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 6 Calibration 6 2 2 Calibration movement dire...

Page 563: ...lar shaft Cabling is twisted axis 4 is positioned at wrong turn rotated more than 360 Cabling is straight axis 4 is positioned at correct turn xx1900001236 xx1900001237 Step 1 Manually running the manipulator to the synchronization position Use this procedure to manually run the manipulator to the synchronization position Note Action Select axis by axis motion mode 1 See Synchronization marks and ...

Page 564: ...ne 5 The calibration options are displayed Tap Revolution Counters 6 In the Selection column select the axes for which revolution counters need to be up dated 7 Tap Update A dialog box is displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update and a confirmation w...

Page 565: ...ovable calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the FlexPendant WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB Using other pins in the calibration bushings may cause severe damage to the robot and or personnel WARNING The calibration tool must be fully ins...

Page 566: ... the current state of the robot is stored and not the state when the robot left the ABB factory The reference value will be named according to tool name date etc Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values When reference calibration is performed the robot is restored to the status given by the reference values Update revolution c...

Page 567: ...System containing SafeMove SafeMove will lose its synchronization to the controller if a new calibration is done New calibration values have to be downloaded to SafeMove and a new SafeMove calibration has to be done Make sure that the user rights admit to change the safety settings and to synchronize SafeMove How to calibrate an inverted robot The IRB 5720 is calibrated inverted in factory prior t...

Page 568: ...damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools Required if Axis Calibration is the valid calib ration method for the robot 3HAC074564 001 axes 1 2 3 and 4 3HAC074119 001 axes 5 and 6 Calibration toolbox Ax is Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube inser...

Page 569: ...d solution Note Action It is possible to use any RFID solution with the correct dimensions ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices 13 56 Mhz according to ISO 14443 or ISO 15693 Note The maximum dimensions on the RFID chip must not exceed Ø7 9 mm x 8 0 mm Ø5 9 mm x 8 0 mm or Ø3 9 mm x 8 0 mm depending on calibra tion tool size 1 There is a ca...

Page 570: ...pin and a bushing for the movable calibration tool are located on each axis as follows If there is not enough space on an axis to install a fixed calibration pin the axis is equipped with two bushings instead for installation of two calibration tools when calibration is carried out This is shown in the figure xx2100002320 Continues on next page 570 Product manual IRB 5720 3HAC079195 001 Revision A...

Page 571: ...Replace damaged parts with new Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushings 3HAC064875 001 axes 1 2 3 and 4 3HAC059487 001 axes 5 and 6 Protection cover and plug set Product manual IRB 5720 571 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 6 Calibration 6 4 3 Installation locations for the calibration tools Cont...

Page 572: ...cover and plug set Overview of the calibration procedure on the FlexPendant The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step Use the following list to learn about the calibration procedure before running the RobotWare program on the FlexPendant It gives you a...

Page 573: ...l affect the calibration value 2 Starting the calibration procedure Use this procedure to start the Axis Calibration routine on the FlexPendant Note Action Tap the calibration icon and enter the calibration main page 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question Note For RobotWare 7 the mechanical unit page is displayed...

Page 574: ...calibration tool is in contact the robot axis needs to be jogged in order to release the calibration tool Jogging the axis in wrong direction will cause the calibration tool to break Directions of axis movement is shown in Calibration movement directions for all axes on page 562 Axis Calibration with SafeMove option To be able to run Axis Calibration SafeMove needs to be unsynchronized The Axis Ca...

Page 575: ...es 1 2 3 and 4 3HAC059487 001 axes 5 and 6 xx1500000952 Reinstall the protective plug and sealing in the bushing on each axis directly after the axis has been calibrated Ensure that the sealing is not damaged Replace the plug and the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC064875 001 axes 1 2 3 and 4 3HAC059487 001 axes 5 and 6 Product manual IRB 5720 ...

Page 576: ...ibration 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 val...

Page 577: ...ce 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 ...

Page 578: ...ition 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 561 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 the lower arm 578 Prod...

Page 579: ...rrectly 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 o...

Page 580: ...This page is intentionally left blank ...

Page 581: ...d 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 w...

Page 582: ...ibilities 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 582 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 7 Troubleshooting 7 1 Introduction to troubleshooting Continued ...

Page 583: ...f the oil spill is small this step is sufficient Wipe off the oil or grease see Cleaning the IRB 5720 on page 183 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 purchased from your local ABB representat...

Page 584: ...e 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 maintenance schedule 2 If a bearing is emitting the noise determine which one and make sure that it has suffi cient lubrication 3 If possible disassemble the jo...

Page 585: ...tat ive Too hot gearbox oil may be caused by Incorrect oil quality or level The robot work cycle runs a specific axis too hard Investigate whether it is possible to program small cooling periods into the application Overpressure created inside gearbox 8 Product manual IRB 5720 585 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 7 Troubleshooting 7 3 Mechanical noise or dissonance ...

Page 586: ...ounding 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 com...

Page 587: ...erials 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 Wrist house tilt house covers connection box mo tor housing Aluminium Serial measurement board Batteries Lithium Calibration protection cap and plug and couplings connectors and nuts in cable harness...

Page 588: ...ible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulations Do not dispose of oil and grease near lakes ponds ditches down drains or onto soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills can form a film on water surfaces causing damage to organisms Oxyg...

Page 589: ...chapter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 5720 589 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 9 Reference information 9 1 Introduction ...

Page 590: ... 1 General requirements normative reference from ISO 10218 1 IEC 60204 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity 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 f...

Page 591: ...y 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 Product manual IRB 5720 591 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 9 Reference information 9 3 Unit conversion ...

Page 592: ...carded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Generally screws are lubricated with Gleitmo 603 mixed with Geomet 500 or Geomet 702 in proportion 1 3 Geomet thickness varies according to screw dimensions refer to the following Geomet thickness Lubricant Dimension 3 5 μm Gleitmo 603 Geomet 500 M6 M20 any length ex...

Page 593: ...tening technique that is do not jerk Tighten the screw in a slow flowing motion Maximum allowed total deviation from the specified value is 10 Oil lubricated screws with slotted or cross recess head screws The following table specifies the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws Note A special torque specified in the repair maintena...

Page 594: ...screws lubricated with Molycote 1000 Gleitmo 603 or equivalent with allen head screws Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 lubricated i Tightening torque Nm Class 10 9 lubricated i Dimension 35 28 M8 70 55 M10 120 96 M12 300 235 M16 550 460 M20 950 790 M24 i Lubricated with Molycote 1000 Gl...

Page 595: ...ccessory 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 Product manual IRB 5720 595 3HAC079195 001 Revision A Copyright 2022 ABB All ...

Page 596: ...oolkit Rem Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 10 30 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 1 Hexagon headed screw M10x100 2 Hexagon headed screw M16x90 1 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm...

Page 597: ... toolkit on page 596 and of special tools listed directly in the instructions and also gathered in this section Special tools Note If the replacing procedure is not listed in the table below only standard tools are needed for the procedure Continues on next page Product manual IRB 5720 597 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 9 Reference information 9 7 Special tools ...

Page 598: ...880 001 1 xx2100002289 Replacement tool for arm house cover 3HAC079878 001 2 2i 2 2 2 Removal tool motor M12 3HAC14631 1 2i 2ii Removal tool motor M10 3HAC14972 1 2ii Removal tool motor M8 3HAC080346 001 2 Screws M8x75 fully threaded 2 Screws M10x60 fully threaded 1 1 1 1 1 1 Bits extender 3HAC12342 1 1 Bit holder 3HAC029090 001 Lifting accessories 1 1 Roundsling 1 m 1 1 Roundsling 1 5 m 1 Lifting...

Page 599: ... xx2200000205 Lifting adapter 3HAC081565 001 1 1 xx2100002415 Lifting accessory for gear 3HAC081585 001 1 1 Lifting accessory motor 3HAC15534 1 1 1 1 Fender washer 1 1 1 1 xx1200001241 Lifting accessory chain 3HAC15556 1 1 1 1 xx1200001242 Lifting eye 3HAC16131 1 1 xx1200001243 Lifting shackle Guide pins 2ii Guide pin M6x150 3HAC080345 001 Continues on next page Product manual IRB 5720 599 3HAC079...

Page 600: ...56 3 1 Guide pin M16x150 3HAC13120 2 1 Guide pin M16x200 3HAC13120 3 Brake release 1 1 1 1 1 1 1 1 1 1 1 xx2100000666 Brake release tool 3HAC081310 001 Calibration tools 1 1 1 1 1 1 1 1 1 1 Calibration toolbox Axis Calibration 3HAC074564 001 axes 1 2 3 and 4 3HAC074119 001 axes 5 and 6 Adjustment and fixing tools 1 1 1 1 1 1 1 1 Rotation tool 3HAB7887 1 1 1 Adjustment tool for gear 3HAC080331 001 ...

Page 601: ...ent with spare part number These tools can be ordered from ABB 1 1 xx2100002608 Lifting and turning tool 3HAC073537 001 1 1 xx2200000207 Fork lift accessory set 3HAC058825 001 1 xx1600002093 Oil level gauge 3HAC061881 001 1 Lifting accessory motor inverted robot 3HAC081586 001 Continues on next page Product manual IRB 5720 601 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 9 Refe...

Page 602: ...motor Axis 3 motor Axis 2 motor Axis 1 motor Tools and equipment with spare part number These tools can be ordered from ABB xx2100002816 i IRB 5720 180 2 6 IRB 5720 155 2 6 LID ii IRB 5720 125 3 0 IRB 5720 90 3 0 LID Continues on next page 602 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 9 Reference information 9 7 Special tools ...

Page 603: ...iece of lifting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories The instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 5720 603 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved 9 Reference information 9 8 Lifting accessories and lifting instructions...

Page 604: ...This page is intentionally left blank ...

Page 605: ...g function 33 C cabinet lock 27 cable harness inspecting 115 refitting 280 removing 260 cabling between robot and controller 97 calibrating robot 565 roughly 563 calibrating robot 565 calibration Absolute Accuracy type 558 rough 563 standard type 558 verification 578 when to calibrate 560 calibration Absolute Accuracy 559 calibration manuals 559 calibration marks 561 calibration position jogging t...

Page 606: ...ntenance 103 inverted mounting 77 L labels robot 19 leak down test 188 leaking sealing 583 lifting robot 64 66 robot down 195 lifting accessory 595 limitation of liability 15 lithium disposal 587 Lithium disposal 587 loads on foundation 37 lock and tag 27 lubricants 29 lubrication amount in gearboxes 141 type of lubrication 141 M magnesium disposal 588 maintenance intervals 103 maintenance schedul...

Page 607: ... robot 19 test run 100 safety devices 27 safety signals in manual 17 safety standards 590 scales on robot 561 schedule of maintenance 103 screw joints 592 securing robot 71 securing the robot to foundation attachment screws 71 signals safety 17 SMB battery replacing 180 SMB unit replacing 313 standards 590 ANSI 590 CAN 590 steel disposal 588 storage conditions 39 symbols safety 17 synchronization ...

Page 608: ...ete 518 532 wrist 245 working range 50 robot 41 wrist replacing 238 X xx replacing 55 65 Z zero position checking 579 608 Product manual IRB 5720 3HAC079195 001 Revision A Copyright 2022 ABB All rights reserved Index ...

Page 609: ......

Page 610: ...ne 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics Discrete Automation No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics Discrete Automation 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC079195 001 Rev A en Copyright 2022 ABB All rights reserved Specifications subject to change without notice ...

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