Product Manual Irb580

Product manual
IRB 580
Title page
Product manual
IRB 580
3HNA010055-001 en Rev.12
First edition: 01 April 2008
Last revised: 15 October 2014
Product manual, IRB 580
The information in this manual is subject to change without notice and should not be construed
as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this
manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be construed
as any kind of guarantee or warranty by ABB for losses, damages to persons or property,
fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from use of this
manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABBs written
permission.
Additional copies of this manual may be obtained from ABB.
The original language for this manual is English. Any other languages that are supplied have
been translated from English.
Copyright 2008-2014 ABB All rights reserved.
ABB AS, Robotics
Discrete Automation and Motion
N-4340 BRYNE, Norway
Table of Contents
Table of Contents
Title page
Preface
1 Introduction
11
2 Safety
13
3 System Description
17
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Basic Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Design Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3 Purge Air Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4 Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 The Horizontal Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Horizontal Arm and Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 Hollow Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 The Vertical Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 The Base and Foot Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.1 Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.2 Balancing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.3 Axes Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.4 The Foot Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 The Axes Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Boards Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Technical Specifications
4.1
4.2
4.3
4.4
4.5
4.6
4.7
35
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manipulator Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manipulator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hollow Wrist Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Permitted Load on Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Working Area Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Installation and Commissioning
6 Preventive Maintenance
49
49
51
52
54
55
57
59
60
61
62
64
65
67
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Axis Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricate Hollow Wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricate Balancing Spring Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Oil Level in Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
36
37
39
42
43
46
49
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.2 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Lifting and Transporting the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Positioning the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Alignment and Levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Securing the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Working Area Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.1 Axis 1 Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.2 Axis 2 Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.3 Elbow Joint Limitation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8 Concluding Activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
6.2
6.3
6.4
6.5
6.6
6.7
17
18
18
19
20
21
22
22
24
25
27
27
28
29
30
31
32
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69
70
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Table of Contents
7 Repair
75
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Releasing Axis Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2 Brake Release Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.3 Manually Releasing Axis Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Base Unit Guidelines
............................................................
7.3.1 Removal of Motor for Axis 1, 2, 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 Installation of Motor for Axis 1, 2, 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3 Removal of Axis 1 Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.4 Installation of Axis 1 Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.5 Disengage Balancing Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.6 Engage Balancing Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.7 Removal of Balancing Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.8 Installation of Balancing Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.9 Adjusting Balancing Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.10 Replace Oil for Axes 1, 2, 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Vertical Arm Guidelines
..........................................................
7.4.1 Removal of Vertical Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2 Installation of Vertical Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.3 Removal of Vertical Arm Lower Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.4 Installation of Vertical Arm Lower Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.5 Removal of Bearings in Parallel Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.6 Installation of Bearings in Parallel Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Horizontal Arm Guidelines
........................................................
7.5.1 Removal of Horizontal Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.2 Installation of Horizontal Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.3 Removal of Horizontal Arm Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.4 Installation of Horizontal Arm Drive Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.5 Removal of Motors in Horizontal Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.6 Installation of Motors in Horizontal Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.7 Removal of Wrist Transmission Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.8 Installation of Wrist Transmission Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.9 Replace Oil for Horizontal Arm Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6 Hollow Wrist Unit Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.1 Removal of Wrist Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.2 Installation of Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.3 Removal of Wrist Inner Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.4 Installation of Wrist Inner Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.5 Replace Wrist Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7 Replacing Cable Units
...........................................................
7.7.1 Removal of Cables Horizontal - Vertical Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.2 Installation of Cables Horizontal - Vertical Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.3 Removal of Cables Vertical Arm - Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.4 Installation of Cables Vertical Arm - Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.5 Removal of Cables Base Unit - Foot Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.6 Installation of Cables Base Unit - Foot Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8 Calibration Fixture Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.2 Calibration Fixture Installation, Axes 1,2,3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.3 Calibration Fixture Installation, Hollow Wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Decommissioning
183
9 Reference Information
185
9.1
9.2
9.3
9.4
75
77
77
78
79
83
84
87
90
93
95
98
100
102
104
106
109
110
113
115
117
119
122
125
126
130
133
136
138
141
144
146
149
151
152
154
156
159
161
163
164
166
168
170
172
174
177
177
178
180
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Instructions for Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Instructions for Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents
9.5 Loctite Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6 Safety Instructions for Replacing Oil in Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7 Oil Type Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7.2 Robot Types Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8 Grease Type Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3HNA010055-001 en Rev.12
Table of Contents
3HNA010055-001 en Rev.12
Preface
About this manual
This manual provides information and instructions for installation, replacing parts
and performing preventive maintenance on the IRB 580 robot, type IRB 580-12.
The manual also covers the manipulator part of models such as IRB 580-13, -14 etc.
(trolley robots). The different types of trolleys and the rail system are described in
separate manuals.
WARNING! Before performing any work described in this manual, the Safety
Manual must be read and understood. Work must only be performed by skilled
personnel with the proper training.
The Safety Manual is included in the Software and Documentation DVD following
each robot, and is also shipped with the robot as paper copy, included in the control
cabinet.
3HNA010055-001 en Rev.12
10
3HNA010055-001 en Rev.12
1 Introduction
1 Introduction
About This Manual
This manual contains information on the following:

Mechanical and electrical installation of the manipulator.
Description of the design of the manipulator.
Technical specifications for the manipulator.
Maintenance of the manipulator.
Mechanical and electrical repair of the manipulator.
Usage
This manual should be used during:

Installation.
Maintenance work.
Repair work.
Who Should Read This

Manual?
This manual is intended for:

Installation personnel.
Maintenance personnel.
Repair personnel.
Prerequisites
The reader should:

Be a trained maintenance and repair craftsman.
Have the required knowledge of mechanical and electrical installation,
maintenance and repair work.
Organization of
Chapters
The manual is organized in the following chapters:

Chapter
Description
1. Introduction
This chapter.
2. Safety
Information on safety.
3. System Description
Information on function and design of the manipulator.
4. Technical Specifications
Specifications for the manipulator, working area drawings,

calculating load on arm etc.
5. Installation and Commissioning
Information about installation of the manipulator.
6. Preventive Maintenance
Information about maintenance work, including schedules.
7. Repair
Information about repair work, including brake release

information and mounting of calibration fixture.
8. Decommissioning
General information for decommissioning the manipulator.
9. Reference Information
Information such as mounting instructions for bearings and

seals, screw tightening torques and oil types.
3HNA010055-001 en Rev.12
11
1 Introduction
References
Following manuals are referred to in this manual:

Manual
Description
Safety Manual
3HNA008924-001
This manual must be read before any work on the robot

is performed.
Product Manual, Control Cabinet IRC5P Includes information on installation of purge unit.
3HNA009834-001
12
Unit Description, Paint

3HNA012856-001
Includes technical description of the units used in the

paint system.
Unit Description, IRC5P

3HNA009628-001
Includes technical description of the control system

electronics etc.
Operators Manual, IRC5P

3HNA008861-001
Includes description of the calibration function and

procedure for entering calibration data etc.
Technical Reference Manual System Parameters

3HAC17076
Includes information on setting of software working

area limitations, defining arm load and defining arm
check point.
3HNA010055-001 en Rev.12
2 Safety
2 Safety
Safety Information
Before performing any work described in this manual, it is extremely important that
all safety information is observed!
There are general safety aspects that must be read through, as well as more specific
safety information that describes danger and safety risks when performing the
procedures. Read the Safety Manual before performing any service work.
WARNING! Before performing any work described in this manual, the Safety
Manual must be read and understood. Work must only be performed by skilled
personnel with the proper training.
Important: The description in this chapter is intended as a short reference and is no
substitute for reading the complete Safety Manual.
General hazards
The following lists some of the most relevant hazards.

Before you enter the spray booth, make sure that all robots and other equipment
have stopped, and also make sure that you wear appropriate safety clothes,
antistatic shoes, gloves, safety glasses, etc. In case of danger for toxic gases,
make sure that you wear appropriate safety equipment.
Always attend to your personal safety.
The motion of the manipulator is powerful. Always make sure that nobody is
within the reach of the robot when running the robot for test etc.
The manipulator is normally installed in an ex-area where there are risks of
explosion. Always consider these risks when working with the robot system and
bringing tools and equipment into the area.
Always be aware of hazards associated with electric power when working with
the robot system.
The use of thin layers of non-conductive plastics for covering parts of the
manipulator against exposure of coating materials must be avoided, as they
could present a hazard of propagating brush discharges.
Releasing the robot axis brakes can be potentially dangerous. Never release the
brakes unless you know the risks involved.
Electronic units are sensitive to static electricity. It is extremely important that
these units are handled with care in order not to damage the boards or introduce
errors.
Do not disconnect any connectors, except service ports, while power is applied
to the controller.
Specific hazards
The following lists some hazards specific for the manipulator described in this
manual.
3HNA010055-001 en Rev.12
13
2 Safety
Always be aware of the potential risk of getting fingers squeezed by the gear rod.
Using various types of spraying equipment etc. may involve use of volatile,
toxic, flammable, combustible, etc., fluids under high pressure and/or high
temperature. All necessary measures must be taken to avoid injuries to people
and environment from these fluids. Check data sheet for the specific fluids.
Always be aware of the fact that you may change the zone classification when
working with volatile fluids.
Always be aware of hazards related to the applicator. These can be dangers
related to the electrostatic high voltage or the bell cup on the bell atomizer.
Safety regulations for use of electrostatic spraying equipment must ALWAYS be
followed.
The high voltage must be switched Off before approaching the applicator, the
high voltage generator, the high voltage cable or any other component of the
high voltage system.
The bell cup is extremely dangerous as it has sharp edges and rotates at an
extremely high speed. The applicator must not be approached before the turbine
air has been switched Off, brake air has been applied and the bell rotation speed
has been reduced to less than 1000 rpm. Observe that the bell cup can rotate for a
long time after it has been switched Off.
The bell cup must only be handled by personnel who are aware of all risks
involved.
Observe before service
Following points must be observed before any service work is started:

Turn off all electric power, fluid supply and pneumatic pressure to the
manipulator.
Residual energy may be present in pneumatic systems, so after shutdown,
particular care must be taken. The pressure in pneumatic systems must be
released before repair can be started. Dump valves should be used in case of
emergency.
Motors and gears are HOT after running the manipulator. Touching the motors
and gears may result in burns. Allow motors and gears to cool down before
touching them.
Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed. All work described in this manual must be performed exactly
as described in the procedures.
Removing an axis motor will disengage the brake function. For this reason, the
axis motor must never be removed while other repair work is being performed.
No other repair work must be performed if one or all of these motors are
removed.
14
3HNA010055-001 en Rev.12
2 Safety
Use only items listed in the Spare Parts Catalogue to avoid possible damage to
the robot or degradation of its performance or affect the ex-certification of the
robot.
Observe before
concluding service
Following points must be observed before performing the first test run after a
service activity (installation, maintenance, repair):
When reassembling components in the system, make sure that the components
are properly secured to avoid hazardous situations from parts thrown from the
robot by high accelerations, high fluid pressure etc.
All service tools and other foreign objects are removed from the manipulator.
All normal safety equipment is installed properly, such as pendant enabling
device.
When service work is finished, the calibration position should always be
checked.
All personnel are standing at a safe distance from the manipulator, out of reach
outside the spray booth or behind any safety fences, etc.
Special attention is paid to the function of the part which has been serviced.
3HNA010055-001 en Rev.12
15
2 Safety
16
3HNA010055-001 en Rev.12
3.1 Introduction
3.1 Introduction
About this Chapter
This chapter provides information on the mechanical function and design of the
IRB 580 manipulator.
The chapter includes description of the different components of the manipulator,
and must only be used for reference purposes.
WARNING! Repair work on the manipulator must only be performed in accordance
with procedures given in the Repair chapter in this manual.
3HNA010055-001 en Rev.12
17
3.2 Basic Design
3.2 Basic Design

3.2.1 Design Overview
General
The IRB 580 is a lighter painter robot in the IRB robot family. The robot is
controlled by 6 axes and has the hollow wrist which enables paint- and air supply
hoses to be laid internally in the robot arm. The robot is approved for installation in
a hazardous area.
Figure 1 Axes overview
Horizontal arm
Axis 4
Hollow wrist
Axis 6
Motor 4, 5, 6
Axis 5
Axis 3
Parallel rod
Vertical arm
Axis 2
Motor 3
(on opposite side)
Motor 2
Motor 1
Axis 1
Identification
plate
Base unit
Foot unit
Axis 1
The drive motor is located inside the manipulator base unit, and controls the
sideways motion of the complete arm assembly via a gear unit. The rotation may be
limited by altering the position of mechanical stop clamps on the foot unit.
Axis 2
The drive motor is located on the right side (rear view) inside the manipulator base,
and controls the forward/backward motion of the vertical arm. The motion may be
limited by installing stop studs.
Axis 3
The drive motor is located on the left side (rear view) inside the manipulator base
and controls the up/down motion of the horizontal arm via the parallel rod.
Axes 4-6
The drive motors for axes 4-6 are located in the rear end of the horizontal arm and
control the motion of the wrist via 3 drive shafts and gear wheels.
18
3HNA010055-001 en Rev.12
3.2 Basic Design
3.2.2 Component Identification

General
The following gives a short overview of the different components of the robot.
Figure 2 Manipulator components
Standard horizontal arm
Short horizontal arm
Vertical arm
Base unit cover
Base unit
Standard foot unit
Horizontal Arm
The horizontal arm is available in a standard- and a short version, it is equipped with
the hollow wrist. The hollow wrist is designed from 3 sections with internal gears.
The wrist is operated by 3 motors via shafts and gear wheels, that are located in the
rear housing of the horizontal arm.
Vertical Arm
The vertical arm includes control electronics for the manipulator and paint control.
The parallel rod is used to transfer power from the drive motor for axis 3 to the
horizontal arm. The vertical arm is equipped with axis brake release switches.
Base Unit
The base unit includes motors and gear boxes for controlling the 3 main axes, and
balancing springs for axes 2 and 3.
Foot Unit
The foot unit includes connections for electrical cable from the control cabinet.
3HNA010055-001 en Rev.12
19
3.2 Basic Design
3.2.3 Purge Air Routing

General
The robot is supplied by compressed air to the parts of the robot which include
electrical components.
Figure 3 Purged area of IRB 580
Purge air
exhaust
Purge sensor
Flexible hose from

purge unit
Description
= Purged area
The air from the purge unit is entered into the foot unit via the flexible hose which
also includes electrical cables. From the foot unit, the air is routed via the base unit
and vertical arm to the rear section of the horizontal arm.
For more information on the purge system, see Unit Description, IRC5P.
20
3HNA010055-001 en Rev.12
3.2 Basic Design
3.2.4 Identification Plate

Description
Identification plates indicating the type of robot and serial number etc., are found on
the control cabinet, purge unit and manipulator.
The identification plate is located on the foot unit or trolley, depending on robot
version.
Note: The identification plate shown in the illustration below only serves as
example. For exact identification, see plates on your robot.
Figure 4 Robot identification plate

II 2 G Ex ib px IIB T4
ABB AS, Robotics
II 2 D Ex pD 21 T65C
Serial No.
PO Box 265, N-4349 Bryne
0470
APPROVED
Batch
Type:IRB 540/580-
Model:
Volume enclosure:
NEMKO 04ATEX1016X
Class I,II. Div.1, Group C,D,E,F,G 135C (T4)"Type X Pressurization"
Ref.Dwg.No.:....................
3HNE 03241-1
Inert gas:..........................
Instrument air
Purge time:......................
Min.supply Inert gas:.......
Max. pressure enclosure:
Min. maintenance press.:
180sec.
470Nl/min.
350mbar
0.8mbar Supply press. 2.4-3 bar
Max. leakage comp.:.......
20Nl/min. (1 bar input)
3HNA010055-001 en Rev.12
21
3.3 The Horizontal Arm

3.3.1 Horizontal Arm and Drive Unit
General
The horizontal arm is located on top of the vertical and is used to perform the up /
down motion of the applicator.
Figure 5 The horizontal arm
Hollow wrist
Horizontal arm
Axis 4-6 drive shafts
Drive unit
Rear housing
Motor axis 5
Oil filling
Axis 4-6 gearbox
Connector
bracket
Gear wheel axis 4

Gear wheel axis 6
Resolver
(inside motor)
Wrist Control
Gear wheel axis 5

Motor axis 6
Motor axis 4
Oil drain
The hollow wrist is located at the front of the horizontal arm. The wrist is attached
to the arm with 4 attachment screws. The drive unit for the wrist includes 3 motors
and is located at the rear end. The motion of the drive unit motors is transferred to
the wrist by means of 3 drive shafts.
The main feature of the hollow wrist arm is that paint and air supply hoses for the
applicator are laid internally in the arm. The hoses are entered into the rear entrance
and connected directly to the applicator / bracket assembly.
22
3HNA010055-001 en Rev.12
Drive Unit Axes
Each of the 3 links of the hollow wrist is controlled by a motor in the drive unit via
a drive shaft through the arm.
The 3 motors are mounted on a gear unit. The gear unit is accessible from the
outside, and includes plugs on top and bottom for oil filling and draining. The gear
box also includes adjustment screws for adjusting the play in the motor / gear box
gears.
Electrical Connections
Two electrical cables with connectors extend from each of the drive motors. These
cables are the motor cable, including motor power, brake power and temperature
sensor connection, and the resolver cable.
Purge System
The purge system applies compressed air to the rear chamber of the arm. A purge
sensor system is located inside the chamber. The sensors are monitored by the purge
control system in the control cabinet to control the function of the purge system.
The purged chamber is an air tight compartment. It is for this reason important that
all screws are installed to prevent air leaks.
Horizontal Arm Support
The arm is supported on bearings on top of the horizontal arm. The motion of the
arm is controlled by the axis 3 drive motor on the turning unit via the parallel rod
attached at the rear end of the arm.
References
For details on the paint systems on the arm, and paint components in general, see
Unit Description, Paint manual.
3HNA010055-001 en Rev.12
23
3.3.2 Hollow Wrist Unit

General
The hollow wrist is mounted to the front of the horizontal arm, and its purpose is to
position the applicator in space. The motion of the wrist is controlled by 3 drive
motors in the rear end of the horizontal arm.
Figure 6 The hollow wrist
Gear wheel
axis 5
Wrist main
bearing
Axis 4
Axis 6 - rotation
Hole for applicator

supply hoses
Axis 5
Drive shaft axis 5
Drive shaft axis 6
Gear wheel axis 4
Drive shaft axis 4
Gear wheel axis 6
Grease nipples
Design
The wrist is built up from 3 rotating sections. Each section is controlled by gear
wheels at the rear end of the wrist and gear wheels within the wrist. Each of the 3
sections may thereby be rotated, and the result is complete flexibility to point the
applicator in any direction and to rotate the applicator.
Gear System
Each of the hollow wrist rear end gear wheels is driven by a small gear wheel on
each of the 3 drive shafts.
24
3HNA010055-001 en Rev.12
3.4 The Vertical Arm

General
The vertical arm joins the horizontal arm with the base unit.
Figure 7 The vertical arm
Vertical arm upper bearing
Parallel rod upper bearing
Electronic compartment
access panel
Parallel rod
Axis brake release switches
Parallel rod lower bearing
Vertical arm lower bearing

Vertical arm right side (rear view)
Design
The arm is supported in bearings at the lower end and includes bearing at the top for
the horizontal arm. The parallel rod transfers force from the turning unit gear box to
the horizontal arm.
Note: The grease nipple in the top bearing of the parallel rod is only used to press
out the bearing for service purposes, and must NOT be lubricated for normal
maintenance, as this may damage the bearing.
Length
The vertical arm has length of 1000 mm.
Control Electronics
The vertical arm includes the manipulator transfer board MTB-01 for manipulator
and paint control. The board is located in the electronics compartment inside the
arm. The compartment is accessible via a cover on the front of the arm.
Axis Brake Release
The vertical arm is equipped with axis brake release switches. The brake release
switches are designed to facilitate manual brake release, if the robot has stopped in a
position and the pendant can not be used to move the robot out of this position.
3HNA010055-001 en Rev.12
25
The three turn and hold switches are installed on the front of the vertical arm. Each
of the switches releases the motor brakes of a pre-defined group of robot axes:
1. Brakes of axis 1, axis 4-5-6 and axis 7 (trolley linear axis if applicable)
2. Brake of axis 2
3. Brake of axis 3
Important: It must be observed that the robot arms may drop or rise when the
brakes are released. This applies especially when extra paint equipment is installed
on the robot arms.
The brake release switches are explosion protected Exi/Exp for use in hazardous
areas.
26
3HNA010055-001 en Rev.12
3.5 The Base and Foot Unit

3.5.1 Base Unit
General
The base unit is located on top of the foot unit. The unit includes drive motors for
the 3 main axes, axes 1, 2 and 3. The vertical arm and parallel rod for the horizontal
arm is attached to the drive systems on the base unit.
Figure 8 The base unit
Vertical arm
Parallel rod
Breathing plug
Right side view
Oil filling plug
Rear cover
Axis 2 gear box

Anti backlash unit
Motor axis 3
Balancing spring assy'
Front cover
Motor axis 2
Motor axis 1
Oil drain plug
Filling plug axis 1

Axis 1 gear box
Foot unit
Front
Design
The main parts of the base unit are the gear boxes for axis 1, axis 2 (right side - rear
view) and axis 3 (left side). The vertical arm is mounted directly on the output shaft
of the axis 2 gear unit. The motion of the axis 3 gear unit shaft is transferred to the
horizontal arm via a lever arm and parallel rod. The vertical- and horizontal arms
are counter balanced by balancing springs on the gear boxes. Electrical cables and
purging hose for the vertical arm are routed via a hole in the center of the unit.
The base unit is a completely sealed environment. When installing covers, no
screws must be missing to avoid air leaks which will affect the purging system.
Anti Backlash Unit
Each gear unit is equipped with an anti backlash unit to prevent jerks when the
vertical arm moves over the top of the motion.
Measuring Board
A measuring board, SMU, for measuring the position of the resolvers is located
inside the base unit.
Base Frame Origo
The origo of the base frame for each manipulator type is located at the floor plane in
the center of the rotation of the first axis. For manipulators mounted on a trolley, the
origo is located in the same place relative the centers of rotation for the robot axes.
Base frame origo is shown in the working area drawing, see Working Area
Drawings on page 46.
3HNA010055-001 en Rev.12
27
3.5.2 Balancing System

General
The vertical arm and horizontal arm are balanced in a way that will hold the
manipulator arm in an unchanged position when the mechanical brakes are released.
The balancing is achieved by a spring on each side of the vertical arm. The spring
on the left hand side (rear view) balances the horizontal arm, and the spring on the
right side balances the vertical arm. The springs are covered with housing.
Figure 9 Balancing springs
Roller
attachment screws
Roller
Lever arm
Spring assembly axis 3

Horizontal arm
Design

Vertical arm
The 2 springs operate in the same way. The difference is the attachment for the lever
arm transferring the spring force to the manipulator arm. For the vertical arm, the
attachment is located on the vertical center line when the arm is in neutral position
(straight upwards). For the horizontal arm, the attachment is displaced from the
vertical center line.
WARNING! The springs are tightened to a considerable force. Attempts to release
this force without having the required qualification and knowledge may cause
serious personnel injuries and even death. For this reason: Do not attempt to loosen
spring force unless you know exactly what you are doing. Follow the procedure in
the Repairs chapter before performing this operation.
28
3HNA010055-001 en Rev.12
3.5.3 Axes Motion

General
The illustration shows the layout of the drive system for the vertical and horizontal
arm.
Figure 10 Axes 2 and 3 configuration
Horizontal arm
Parallel
rod
Vertical arm
Parallel rod
Lever arm
Lever arm
Axis 2 gear
Axis 3 gear
Axis 3 motor
Axis 2 motor
Axis 3 motor
Motor and gear

box - rear view
Axis 2 motor
Axis 2 System
The axis 2 motor controls the vertical arm which is mounted directly on the gear box
output shaft.
Axis 3 System
The axis 3 motor controls the horizontal arm via a lever arm attached to the output
shaft and a parallel rod attached to the lever arm.
3HNA010055-001 en Rev.12
29
3.5.4 The Foot Unit

General
The manipulator foot unit serves as a rigid foundation for the manipulator base unit.
Figure 11 The foot unit
Compartment for
electrical connections
Bearing for
base unit mounting
Standard foot unit
Design
Front
The foot unit is made from a solid cast iron unit. The unit includes connectors for
connections between the cables from the controller and the axis motors and control
electronics in the manipulator.
For dimensions of the foot unit and footprint drawing etc., see Foot Unit
Specifications on page 42.
30
3HNA010055-001 en Rev.12
3.6 The Axes Motors
3.6 The Axes Motors

General
Each axis of the manipulator has its own electric motor unit, including a
synchronous motor, a brake and a feedback device (resolver). Different motors are
used for different axes on the robot. The drive shaft of the motor forms a part of the
gearbox of the manipulator axis.
The feedback device and brakes are installed by the supplier of the motor and
should never be removed from the motor. The complete motor assembly should be
replaced as a complete unit.
Motor Power
Power is applied to the motors when the motor power button on the main panel is
pressed.
Feedback Unit
Each motor is equipped with a feedback unit (resolver) for the measuring system,
located on the end inside the motor. The feedback unit is connected to the motor
shaft. The purpose of the unit is to send feedback to the control electronics of the
position of the motor and thereby the manipulator axes via the measuring board.
Axis Brakes
Each motor is equipped with electrical holding brakes. The purpose of the brakes is
to hold the manipulator in unchanged position when power is removed from the
motors. The brakes are active when no power is applied, and released (lifted) when
power is applied. The brakes are automatically released when power is applied to
the motor, but may also be released from the pendant, with the brake release
switches on the vertical arm, or directly on the motor connector etc. for service
purposes. How to release the axis brakes for service purposes is described in the
chapter Repair in this manual.
Temperature Monitoring
Each motor also includes a temperature sensor. If the temperature should increase
over a specified maximum, motor power will be removed and the brakes activated.
Commutation
The motor does not need to be commutated (commutation value is 1.570800).
3HNA010055-001 en Rev.12
31
3.7 Boards Overview
3.7 Boards Overview

General
This section provides an overview of the different manipulator control-, interfaceand connector boards used on the IRB 580 manipulator, and also describes the
location of the boards.
For detailed description of the boards, refer to Unit Description, IRC5P.
Overview
The following boards are used for the IRB 580 manipulator:
Manipulator Transfer Board, MTB-01
Serial Measuring Unit, SMU
For location of the boards, see Figure 12.
MTB-01
The MTB-01 includes following functions:

Manipulator interface (Brake release and temperature sensor monitoring)
Cable connection point between control cabinet and manipulator
The main function of the MTB-01 board is to interface the motor temperature
sensors and the motor brakes with the control cabinet and provide routing for the
CAN bus.
The MTB-01 board is located in the electronic compartment in the manipulator
vertical arm.
SMU
The serial measuring unit measures all the motor positions and reports these to the
axis computer.
The SMU is located in the base unit.
Location
32
The following illustration shows the location of the boards in the manipulator
vertical arm and base unit.
3HNA010055-001 en Rev.12
3.7 Boards Overview
Figure 12 Location of boards in vertical arm and base unit
3HNA010055-001 en Rev.12
33
3.7 Boards Overview
34
3HNA010055-001 en Rev.12
4.1 Introduction
4.1 Introduction
About this Chapter
This chapter provides technical specifications on the IRB 580 manipulator.

WARNING! Repair work on the manipulator must only be performed in accordance
with procedures given in the Repair chapter in this manual.
References
For specifications on the trolley, see Product Manual, Trolley.
3HNA010055-001 en Rev.12
35
4.2 Manipulator Versions
4.2 Manipulator Versions

General
The following provides information on the different versions of the IRB 580 robot.
Figure 13 Manipulator versions
IRB 580-12
Long horizontal arm
IRB 580-12
Short horizontal arm
IRB 580-12
Robot on Clean Wall Trolley
6 axis floor mounted manipulator, equipped with hollow wrist horizontal arm.
Supply hoses for the wrist are routed internally in the wrist and arm.
The manipulator is available with 2 different lengths of the horizontal arm;
1620 mm and 1220 mm.
IRB 580-13
36
7 axis manipulator mounted on the CleanWall type trolley. Except for the foot unit
which is substituted by a trolley, the manipulator is identical to the standard
manipulator.
3HNA010055-001 en Rev.12
4.3 Manipulator Specifications

General Specifications
Number of axes
Weight
630 kg incl. foot unit
Dimensions
See Working Area Drawings on page 46
Payload manipulator
See Permitted Load on Arm on page 43
Payload wrist
Permitted Load on Wrist on page 40
Ex-approved
Explosion protected Exi/Exp for installation in hazardous area

Zone 1 & Zone 21 (Europe) and Division I, Class I & II.
Airborne noise level
< 70 dB (A) Leq (acc. to Machinery directive MD 2006/42/EC)

(The sound pressure level outside the working space)
Ingress protection degree
IP67
Ambient temperature
0C - +40C (Recommended max. ambient temp, <30C) *1
Relative humidity
Max. 95% Non-condensing.

(Complete robot during transportation, storing and operation)
Color specification
Graphite white RAL7035 / Black RAL9005
*1 The temperatures given above do not apply under the following circumstances:
Manipulator is covered with material which restricts heat emission. Robot is
programmed with heavy acceleration/retardation (more than 50% of the duty cycle).
Power Consumption
During a typical continuous
paint process
600W
Axis 1
Rotation of complete robot unit
Axis 2
Vertical arm forwards / backwards
Axis 3
Horizontal arm up / down
Axis 4
Wrist rotation *1
Axis 5
Wrist bending *1
Axis 6
Wrist flange rotation *1
Axis 7
Optional axis for trolley motion
Robot Axes
*1 The wrist axes are shown in Figure 16.

Working Area
Range of motion Axis 1
+150 - -150
+75 - -70
+35 - -60
Working area
See Working Area Drawings on page 46
3HNA010055-001 en Rev.12
37
Performance
Stress Forces
Static repeatability
0.3 mm
Velocity Axis 1
112/s
Velocity Axis 2
112/s
Velocity Axis 3
112/s
Stress forces mean the forces transferred to the foundation during movement of the
robot. Maximum load in relation to the base coordinate system is shown below.
Figure 14 Direction of the stress forces and acceleration
Front
Y
Z
38
Force & Moment
Endurance load in operation
Max. load at emergency stop
Force x,y
2900 N
3500 N
Force z
+ 6200 1000 N
+ 6200 1000 N
Moment x,y
5300 Nm
6000 Nm
Moment z
1500 Nm
3000 Nm
3HNA010055-001 en Rev.12
4.4 Hollow Wrist Specifications

General Specifications
Ingress protection degree
IP54
Standard seals
Viton A
Optional seals
Viton Extreme ETP
Standard the hollow wrist is equipped with Viton A seals. The Viton Extreme ETP
seals provide an increased chemical resistance.
Range of Motion
Axis 4 - Rotation motion
Unlimited
Axis 5 - Bend motion
Unlimited
Axis 6 - Turn motion
Unlimited
Working envelope
140
Velocity Axis 4
465/s
Velocity Axis 5
350/s
Velocity Axis 6
535/s
Performance
3HNA010055-001 en Rev.12
39
Permitted Load on Wrist
The diagram below shows the maximum load which can be handled by the hollow
wrist. The maximum load is depending on the distance and offset from the wrist
flange to the center of gravity of the load.
Note: The wrist load is restricted to 10 kg. This is due to the total handling capacity
of the robot itself, and not related to the wrist. In some cases however, the load may
be increased (depending on load installed on the robot arm etc.). Please contact your
local ABB organization for calculation of possible extra load.
Figure 15 Load diagram for hollow wrist
Distance from flange Z [m]
0.5
10
0.45
10
Centerline
0.4
0.35
10
0.3
0.25
CG
0.2
10
Flange
0.15
0.1
Wrist
0.05
10
0
0
40
0.05
0.1
0.15
0.2
0.25
0.3
3HNA010055-001 en Rev.12
0.35
0.4
0.45
0.5
Distance from
centerline R [m]
Basic Design
The illustration below shows the basic design of the hollow wrist with the inner
flexible tube and including an example of an applicator attachment and an
applicator. The illustration also shows the dimensions for the mounting flange on
the wrist front. The information may be used for making an applicator attachment
etc.
Figure 16 Hollow wrist, basic design
Hollow wrist unit
71 hose guide tube
Applicator
attachment
Applicator
Horizontal arm
Center hole
Supply hoses
Connection
Inner flexible tube

Axis 4
140 Degr.
Axis 6
A
Attachment holes
10xM6 Depth 10mm
Axis 5
Holes for alignment pins

on attachment 2x4H7
102
116
63
93H8
TCP Reference point
12x30
FRONT
A
FRONT VIEW
3HNA010055-001 en Rev.12
Inner tube
Section A-A
41
4.5 Foot Unit Specifications
4.5 Foot Unit Specifications

Description
The foot unit is the base for the floor mounted robot. All painting robots and door
opener robot use identical base as standard.
The illustration below shows the manipulator standard foot unit with measurements
for mounting holes, guide pin holes and overall size.
The weight of the standard foot unit is 150 kg.
190
Figure 17 Foot unit design
REAR
SIDE VIEW
FRONT
Holes for guide pin, 2 x M12 H7
170
Attachment holes:
4 x 14 for M12 bolt
80
500
80
215
15
550
500
7.5
500
8x15
80
8x15
TOP VIEW
Axis 1 stop stud positions
42
3HNA010055-001 en Rev.12
Dimensions in mm
4.6 Permitted Load on Arm

General
Various equipment such as atomizer, air regulation, pilot valves, fluid pumps, color
change valves, etc. may be mounted on the robot arm. Exactly how much that can
be mounted on the arms depends on the position of the load, or more exact, on the
coordinates of the centers of gravity of the load on the vertical arm, the load on the
horizontal arm and the tool load. The following sections describe how to find the
maximum loads which can be mounted on the arm. For information on load which
can be mounted on the wrist, see Permitted Load on Wrist on page 40.
Important Notes
All loads described refer to a naked robot. If extra components are already present,
the weight of these components must be subtracted from the calculated weights.
Keep in mind that any load on the manipulator will reduce the robots capability to
accelerate. As this might have consequences for the cycle time, the load should be
kept as low as possible, and should be mounted as close to the center of rotation or
to the base of the manipulator as possible.
It is of great importance that the controller has an exact description of the extra
loads to be able to generate optimal paths and thus avoiding inaccurate motion
performance. For information, see Technical Reference Manual, System
Parameters, Topic Motion / Type Arm Load.
Configuring less load than is actually mounted on the robot arms will lead to motor
torques exceeding their limits with possible overheating and/or reduction of lifetime
of motors and gear units. This case is not covered by the robot warranty.
Note: Changing the load on the arm may cause the arm to raise or drop, depending
on robot type and installed load.
Maximum Loads
For the amount of paint equipment that can be mounted on the manipulator, the
critical factor for the maximum load is the gravitational torque. An evaluation of the
gravitational torque is normally considered sufficient for determining max. load.
3HNA010055-001 en Rev.12
43
Figure 18 Location of loads on robot arm

1620 / 1220
Imh
Imt
mh
mt
mv
1000
Imv
mv: Mass of load on vertical arm

mh: Mass of load on horizontal arm
mt: Mass of load on tool
lmv: Distance from center of rotation axis 2 to COG of mv
lmh: Distance from center of rotation axis 3 to COG of mh
lmt: Distance from wrist flange to COG of mt
The following formulas are normally sufficient accurate to evaluate the actual
gravitational load:
Vertical arm:
Tgrav=[mv*lmv+(mh+mt*1.0)]*9.8
horizontal arm 1620mm:
Tgrav=[mh*lmh+mt*(1.62+lmt)]*9.8
horizontal arm 1220mm:
Tgrav=[mh*lmh+mt*(1.22+lmt)]*9.8
Mass in kg
Length in m
These values must not exceed the following values:
44
Axis
Maximum gravitational torque

caused by extra load
Maximum moment of inertia

caused by extra load
100 kgm
300 Nm
50 kgm
250 Nm
50 kgm
3HNA010055-001 en Rev.12
Quick Determination of
Maximum Loads
Estimating the extra loads which can be mounted on the robot arm refers to 3 boxes;
box A, B and C as shown in illustration below. The boxes also stretch symmetrically
400 mm to each side of the center line and 230 mm to each side of the horizontal
arm center line, i.e. into- and out from the 2D plane shown in the drawing.
Figure 19 Location of loads on robot arm
400
400
C
230
400
230
A
Wrist load
Arm 3 center line
Arm 1 and 2 center line
Extra load must be mounted with the center of gravity inside the three boxes A, B
and C. Box A applies for load on the vertical arm, and boxes B and C apply for the
horizontal arm. The extra load permitted must comply to the following rules:
Note: If large loads are placed in extreme positions in the boxes, e.g. close to
corners, the method described under Maximum Loads on page 43 should be

applied for verification.
The load information applies both for 1620 mm and 1220 mm horizontal arm.
1.
Sum of load in boxes A and B must not exceed 20 kg.
2.
Sum of wrist load and load in box C must not exceed 15 kg.
3.
If the latter is less than 15 kg, the difference can be added to box A or B.
4.
Maximum 20 kg can be mounted in the base, axis 1, if the distance from the
center of rotation to the center of gravity of the load is less than 400 mm.
3HNA010055-001 en Rev.12
45
4.7 Working Area Drawings

Description
The following pages include following working area drawings:

Figure 20 - IRB 580-12 Long horizontal arm
Figure 21 - IRB 580-12 Short horizontal arm
Note that installation of options such as hose guides etc. may restrict the working
area of the manipulator arm.
For complete AutoCad working area drawings, please contact your local ABB
organization.
46
3HNA010055-001 en Rev.12
Figure 20 Working area IRB 580-12, long horizontal arm

2576
1620
290
170.5
35 max
X axis
3440
1000
70
75
60
Base frame origo
741
378
630
1924
30-150
300
R2576
780
391
150
370
Base frame origo
3HNA010055-001 en Rev.12
47
Figure 21 Working area IRB 580-12, short horizontal arm

2189
170.5
1220
35 max
X axis
2814
1000
70
75
95
344
630
1924
30-150
223
Base frame origo
300
R2189
780
391
150
370
Base frame origo
48
3HNA010055-001 en Rev.12

5.1 Introduction

5.1 Introduction
5.1.1 General
About this Chapter
This chapter provides information for installing the mechanical robot at the working
site.
The chapter includes information on how to lift the manipulator into position, how
to align the manipulator in relation to a conveyor, hints and information on how to
prepare a mounting base for the manipulator, how to limit the motion of the
manipulator axes etc.
Important: This chapter only describes installation of the manipulator. For complete
installation instructions, see also:

Product Manual, Control Cabinet IRC5P for installation of the control cabinet,
Unit Description, Paint for connection of the paint system and
Operators Manual, IRC5P for starting up the robot system.
If the robot is installed on a trolley for rail operation, refer to
Product Manual, Trolley and
Product Manual, Rail System.
Safety Information
Before any work described in this chapter is commenced, it is extremely important

that all information concerning safety is carefully studied.
safety information that describes danger and safety risks related to performing the
procedures. Read the Safety Manual before performing any installation work.
WARNING! No installation work must be performed on the robot before the safety
guidelines in the Safety Manual have been read and understood. Work must only
be performed by skilled personnel with the proper training.
Welding
All welding work at the robot location must be performed before any cables are
connected. Welding on the control cabinet, manipulator or any other components of
the robot system is not allowed. The Welding Safety Precautions found under
Safety Risks Related to Installation in the Safety Manual must be read before
any welding activities are started.
Purge Unit
Installation of the purge unit is the same for all manipulator types and is for this
reason described in Product Manual, Control Cabinet IRC5P.
3HNA010055-001 en Rev.12
49

5.1 Introduction
Utility Needs
Following utilities will be required for the installation and operation of the robot and
paint equipment.
Mains power
Compressed air for purge system (ex-robots) and paint system
Paint supply station
Required Tools and

Items
Most of the installation work can be performed with normal hand tools. Following
special tools will/may be needed:
24 VDC / Min. 5A, power supply for releasing axis brakes
Machine leveller for levelling the manipulator
Environmental
Conditions
For information on environmental conditions, see Safety Manual and

Manipulator Specifications on page 37.
Other Information
For information on floor loading, foot unit template, performance, working area,
load diagram, permitted extra loads on the robot arm, etc., see Technical
Specifications on page 35.
Information such as Circuit Diagrams and Spare Parts Catalogue is available on the
supplied DVD-ROM. For complete information, see README file on DVD-ROM.
For Autocad drawings of working area, please contact your local ABB organization.
Preparing the Installation

Site
Before you start the installation, it is recommended that you make necessary
drawings to establish location of manipulator, control cabinet and other components
to be installed, design a solid mounting base for the manipulator and plan the
location of process equipment, conduits for cables and hoses etc.
Lifting Device
Make sure that the lifting device to be used for lifting the manipulator is
dimensioned to handle the weight of the manipulator. For information on
manipulator weight, see Lifting and Transporting the Manipulator on page 52.
Check for Damage
When unpacking the robot, control cabinet and associated components, check that
they have not been damaged during transportation. If any damage is found,
immediately report this to the producing unit, using the appropriate online tool. Also
check that all components are correctly delivered in accordance with the packing list
attached to the shipping crate.
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3HNA010055-001 en Rev.12

5.1 Introduction
5.1.2 Installation Guidelines

General
The following sections detail the main steps on how to unload, transport and install
the manipulator.
Installation Procedure
Action
Reference
Prepare for installation
What you should be aware of before starting to

install the manipulator is described in section
Introduction on page 49
Lifting and transportation
How to lift and transport the manipulator is

described in section Lifting and Transporting the
Manipulator on page 52
Position the manipulator
How to place the manipulator in correct position is

described in section Positioning the Manipulator
on page 54
Align and level the manipulator
How to align the manipulator with the conveyor and

how to level the manipulator is described in section
Alignment and Levelling on page 55
Secure the manipulator
How to design a mounting base and secure the

manipulator to the foundation is described in
Securing the Manipulator on page 57
Set working area limitations
How to restrict the working range of the

manipulator axes is described in section Working
Area Limitations on page 59
Check electrical connection
The connection of the electrical cable in the

manipulator must be checked as described in
Electrical Connection on page 64
Conclude installation
For general information, see Concluding Activities

on page 65
3HNA010055-001 en Rev.12
51

5.2 Lifting and Transporting the Manipulator

General
The manipulator is shipped on a transportation pallet in an upright position. The

manipulator arm is folded to reduce packing size.
Manipulator weight: Approx. 600 kg
Figure 22 Manipulator lifting position
Lifting strap attachment to hook
Procedure
The following procedure describes how to unpack the manipulator, release the axis
brakes and lift the manipulator.
WARNING! The robot arm is folded before shipment for packing purposes. To
prevent the robot from tipping over, the arm must be placed in a stable position as
shown above before removing screws securing robot to transportation pallet.
1.
After having unloaded the manipulator crate from the lorry, use a fork lift and
transport the manipulator to the installation site or as close to the site as
possible before removing it from the pallet.
CAUTION! To prevent oil leak from the gearboxes, do not tilt the manipulator more
than 30 during transportation to the installation site.

2.
Unpack the manipulator and supplied packages and check that the content is
correct and undamaged.
WARNING! Do not remove manipulator attachment screws before releasing the axis
brakes.
52
3HNA010055-001 en Rev.12

3.
Release axis brakes by removing base unit cover and applying power to
connector pins. For information on how to release the axis brakes, see
Releasing Axis Brakes on page 77.
Note: A power supply capable of supplying 24 VDC with minimum 5 Ampere
must be available.
4.
Move manipulator arm to a stable position as shown in Figure 22.
CAUTION! Do not rotate the hollow wrist axes at this point.
5.
Remove attachment screws securing manipulator to transportation pallet.
CAUTION! Various paint control equipment may be mounted on the vertical arm
and horizontal arm. When lifting the manipulator, attention must be paid in order
not to damage these components or their panels. If necessary, remove vertical arm
side covers before lifting.
WARNING! The following lifting instructions are valid for a naked robot with
standard arm length. Whenever additional equipment is put on the robot, and/or the
robot arm is of a design different from the standard arm or the arm has been
repositioned in relation to the position shown in the illustration, lifting can be
dangerous and extra attention must be paid when lifting the robot.
6.
Attach lifting straps as shown in Figure 22.
WARNING! Do not walk under the hanging load.
7.
Tension the lifting straps. Check that straps are properly secured and will not
slide. Lift the manipulator vertically.
3HNA010055-001 en Rev.12
53

5.3 Positioning the Manipulator
5.3 Positioning the Manipulator

General
The position of the manipulator should be included in the drawings for the planning
phase for the installation to be able to find the position of foundation arrangements
etc. This position will only be an approximate position as the accurate position can
best be found after the manipulator has been physically placed in the spray booth.
The necessity of finding an exact position for the manipulator depends largely on
the size and shape of the objects which are to be painted. Larger objects require
more accurate trimming of the position of the manipulator to be able to reach all
necessary surfaces.
For information on working area for the robot, see Working Area Drawings on
page 46.
Important Notes
Following points should be observed when planning the position of the manipulator
and trimming the manipulator to the accurate position:
The manipulator must be positioned so that all surfaces to be painted can be
reached.
The distance from the front of the wrist to the point where the spraying fan hits
the object is determined by the spray-gun and TCP (Tool Center Point) distance.
The manipulator must be positioned so that obstructions in the working area for
the manipulator can be bypassed at a safe distance. If this requirement cannot be
met, working area limiting devices must be installed, and necessary guards,
fences etc. must be provided.
The floor must be strong enough to support the weight of the manipulator. In
addition, the floor should deflect as little as possible due to the dynamic forces
from the manipulator. Recommended is a concrete floor or a rigid steel structure.
For more information, see Securing the Manipulator on page 57.
The design of the manipulator gives the arm a considerable reach in backwards
direction. When necessary, this range must be limited using mechanical stops to
prevent the arm from hitting the back wall of the spray booth etc. with an
additional safety clearance of minimum 300 mm. For information on limiting the
working range, see Working Area Limitations on page 59.
Procedure
54
1.
Lift manipulator into position on the prepared mounting base in the spray
booth.
2.
Install attachment screws, but do not tighten yet. Adjust levelling screws until
the manipulator is levelled. Align manipulator perpendicular in relation to
conveyor as described in Alignment and Levelling on page 55.
3.
Tighten attachment screws. Add grease to the screws to prevent corrosion.
3HNA010055-001 en Rev.12

5.4 Alignment and Levelling

General
It is important that the manipulator is correctly levelled and that the straight forward
position of the arm is perpendicular to the conveyor. This is especially important
when using the conveyor tracking feature for synchronizing the robot programs to
the position of the objects on the conveyor.
Figure 23 Manipulator - conveyor alignment
Conveyor
center line
90
Alignment stick
Base/arm center line

-a
+a
Guide pin
hole
Base alignment pins
Foot plate alignment pin
Procedure
Clamp
When the correct distance between the manipulator and the conveyor has been
settled, the complete manipulator must be positioned to be perpendicular to the
conveyor within +/0.5 mm when the manipulator arm (axis 1) is pointing straight
forwards. The alignment can be performed as follows:
WARNING! When the manipulator is not fastened to the floor, the manipulator is not
stable in the whole working area. When the arms are moved, care must be taken to
prevent the manipulator from tipping over. Not paying attention to this hazard can
cause severe injuries to personnel or equipment.
1.
Release axis brakes as described in Releasing Axis Brakes on page 77. Rotate
the manipulator arm until the alignment pins on the base unit and foot unit are
exactly above each other. If the calibration fixture kit is available, install clamp
to lock axis 1 in this position. The arm is now pointing straight forwards in
relation to the base. Move the horizontal arm to a horizontal position.
3HNA010055-001 en Rev.12
55

2.
Activate axis brakes and rotate the complete manipulator until it is as close to
90 as practically possible using eye measure. Level the manipulator roughly.
3.
Attach an alignment stick to the horizontal arm so that it extends e.g. 1 meter in
front of the arm. Make sure that the stick is parallel with the arm and centred in
relation to the arm.
4.
Remove axis 1 clamp. Release brakes and move the arm an angle (+a) in
relation to the base/arm center line. The arm should then be located so that a
defined point on the front of the alignment stick is located near a vertical line
from the conveyor center line.
The angle may be accurately found by reading joint angle for axis 1 on the
pendant.
5.
Measure the distance from the defined point on the front of the alignment stick
to the conveyor center line in vertical direction. If the point on the stick has a
horizontal offset in relation to the vertical line, measure this distance as well.
6.
Move the manipulator arm the same angle (-a) in relation to the center line in
the opposite direction.
Note: Make sure that only axis 1 is moved. Moving any of the other axes will
result in incorrect measurement.
Levelling the
Manipulator
7.
Repeat measurements described in Step 5.
8.
If these measurements are not corresponding, rotate and level manipulator base
to compensate for the difference.
9.
Repeat operation until the measurements are corresponding.
In addition to be aligned perpendicular to the conveyor, it may be important that the

manipulator is levelled. The manipulator may be levelled as follows:
Method 1
Install the manipulator on an accurately levelled base plate.
Method 2
Use a machine leveller at the side of the vertical arm. Turn axis 1 by 90 and control
again. Use the levelling screws and repeat the procedure until the machine levels
show the vertical arm to be vertical in any position of axis 1.
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3HNA010055-001 en Rev.12

5.5 Securing the Manipulator

General
Following description provides information for securing the manipulator to the

floor.
Mounting Surface
Requirements
A solid mounting surface for the manipulator is a precondition for a successful

installation.
A concrete floor is the best type of surface and should be used whenever possible. A
steel construction may also be used provided that the construction has sufficient
strength and stiffness.
If the above surfaces are not available, a mounting base must be designed for the
manipulator. This may be required if the manipulator is to be installed e.g. on a
framework frequently found in spray booths. Remember that the forces go down in
the structure under the made mounting base.
Base Template
The manipulator is secured to the mounting surface using 4 ea. M12 bolts. The 2 ea.
guide pins (M12 with tolerance H7) may be installed to enable accurate
repositioning of the manipulator after the manipulator has been removed for service
etc., or if the position for some reason has been disturbed.
Note: A recommended method for securing the manipulator is to install M12
mounting screws (the attachment holes in the levelling screws are 14). This will
enable trimming of the position before installing the alignment pins.
For drawing and dimensions of the foot unit, see Foot Unit Specifications on
page 42.
Designing a Mounting
Base
When designing a mounting base, following points must be kept in mind. For
information on maximum loads, forces applied to the mounting surface etc., see
Stress Forces on page 38.
The base must be strong enough to carry the weight of the manipulator.
The base must have a stiffness which will minimize swinging related to dynamic
forces in X, Y and Z direction. (A common mistake is to make the mounting
base too weak).
Note that if the object to be painted is mounted to the same structure as the
manipulator, the painted object may be influenced by the manipulator.
If the base is built on H-bars etc., measures should be taken to prevent bending
which may cause oscillations when the manipulator is moving (typically large
up/down paint strokes).
It is recommended that deflection of the structure do not exceed more than
0.3 mm per meter. Exception could be made due to installation. Note that
3HNA010055-001 en Rev.12
57

repeated identical painting movement at a low frequency may match the natural
frequency of a weak under structure.
The base should be made in a size which will enable adjustments to find the most
suitable position of the manipulator in relation to the object.
The mounting surface should be horizontal.
Floor Attachment
The manipulator is recommended to be installed on a concrete floor as shown in the

left illustration, or on a steel plate mounted to concrete or a rigid steel structure as
shown in the right illustration. The mounting screws must be tightened with correct
torque, see Tightening Torques on page 189. Add grease to the screws to prevent
corrosion. The length of the attachment screws must be L=90mm plus length
required for attachment to foundation.
Figure 24 Base securing
M12 Securing bolt
Washer
Washer
Levelling
screw
L
Lock nut
Washer
Fixture tube
Floor mounting: After the mounting location has been found, drill 4 holes in the
floor. Insert the fixture tubes for expansion bolts in the holes. Place the manipulator
on top of the holes, and secured with 4 bolts. The manipulator may be levelled by
adjusting the levelling screw. When level, lock position by tightening the lock nut.
Steel plate mounting: The manipulator may be mounted on a steel plate of minimum
15-20 mm thickness. If the plate is accurately levelled, the levelling screws may be
set to the upper position so that the manipulator will rest on the machined surfaces
on the base legs.
58
3HNA010055-001 en Rev.12

5.6 Working Area Limitations

General
The following sections provide information for limiting the motion of axes 1 and 2,
and the elbow joint.
Important: The software limits must be set to correspond to the changes in the
mechanical limitations of the working range. For information, see Technical

Reference Manual, System Parameters, Topic Motion / Type Arm / Upper joint
bound and Lower joint bound.
3HNA010055-001 en Rev.12
59

5.6.1 Axis 1 Limitation

General
The maximum working area for axis 1 for the floor mounted robot is 150. This
area may be limited by positioning mechanical stop studs on the manipulator foot
unit as shown in the illustration below.
Note: For a trolley robot, axis 1 working area (sideways motion) is fixed to 105
by stop studs under axis 2 and 3 gear units on the robot base and stop studs on the
top of the trolley.
Figure 25 Working area limitation axis 1, top view
Maximum rotation
Software limit
Mechanical stop
Stop device
on rotating
base unit
Stop stud in
center position
Separately supplied
stop stud
Example:
Limited rotation
Procedure
The robot is supplied with 2 stop studs. One of these studs is installed in center
position as shown in the illustration. The other is supplied separately. By positioning
these studs, the working area can be limited according to requirement.
The rotation angles in +/- directions refer to the arm pointing straight forwards.
When installing the stoppers, the area must be kept within the maximum limits
stated above in each direction. The arm must under no circumstances be permitted
to move beyond the maximum limits due to the cable layout in the base.
The working range can be set in increments of 15 degrees.
If the maximum rotation is to be used, the two stop studs must be substituted by one
stud. This stud MUST be installed on the front center as shown in Figure 25.
CAUTION! The stop stud(s) must be installed within a position which limits the
rotation to a maximum of 150 degrees as shown in Figure 25. Incorrect positioning

of the stud(s) or moving the manipulator arm without the studs installed MAY
CAUSE SERIOUS DAMAGE to the cable layout inside the manipulator base.
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3HNA010055-001 en Rev.12

5.6.2 Axis 2 Limitation

General
The maximum working area of axis 2 (forwards/backwards motion) is 145

(+75/-70). This area may be limited by 15, 30 or 45 in each direction by adding
stoppers as shown in the illustration.
Figure 26 Working area limitation axis 2, vertical arm side view
-15
-15
-15
-15
-15
-15
70
75
Fixed
stopper
Additional
stopper
Fixed
stopper
Stop
stud
Stop stud
Stop stud
attachment
screw
Procedure
To add stoppers, remove stop stud from fixed stopper by removing attachment
screw. Then install 1, 2 or 3 stop stud attachments as required. Install stop stud on
the last attachment.
The illustration shows 1 stopper for 15 limitation in backwards direction and no
additional stoppers in forward direction.
3HNA010055-001 en Rev.12
61

5.6.3 Elbow Joint Limitation

General
The following sections provide information for enabling cartesian boundaries for a
defined arm check point. This limitation is typically used for the elbow joint,
formed by the vertical and horizontal axes, to avoid collision with external
equipment, e.g. the spray booth wall.
WARNING! For safety reasons, this software shall not be used for protection of
personnel. Use hardware protection equipment for that.
General Principle
By defining the cartesian boundaries, a box is formed. The defined arm check
point is restricted to operate inside this box. If the check point is moved outside,
either by the operator or by a program, the control system will stop the robot and
issue an error message.
If the arm check point is outside the defined box, only movements towards the
legal area are permitted. Otherwise, the control system will issue an error message,
and the robot will stop.
There is a risk, although very small, that the arm check point under certain
circumstances can move outside of its box in a setup with conveyor tracking.
The robot control system will also monitor the speed of the check point so that it
does not exceed 250 mm/s in Manual Reduced Speed mode (
).
The check point can be a point on the arm itself, or at an external unit attached to the
arm etc.
A graphical description of the principle is shown in the illustration below.
Figure 27 Arm check point limitation
Arm check point
min
max
max
Z
max
min
min
Elbow joint
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3HNA010055-001 en Rev.12

Defining Check Point

and Cartesian
Boundaries
Setting this function is performed in 2 steps; First, the location of the check point
must be established, and then the cartesian boundaries for the box must be entered.
1.
Enter Check Point and Activate Function.

For information on how to enter the location of the check point and to activate
the function, see Technical Reference Manual, System Parameters, Topic
Motion / Workflows / How to define arm check point.
2.
Enter Cartesian Coordinates.

Each of the 6 boundaries defines a plane in space, and together they form a
cartesian volume, a box.
Note: By default, the check point boundaries (cp bound) are zero, and the
control system will not monitor the position of the defined arm check point.
Select the desired parameter as shown below and change its value. See
Figure 27 for information on x,y,z axes etc. The values are entered in meters
[m].
Parameter
Description
Upper cp bound x
Xmax
Upper cp bound y
Ymax
Upper cp bound z
Zmax
Lower cp bound x
Xmin
Lower cp bound y
Ymin
Lower cp bound z
Zmin
For information on how to enter the parameters, see Operators Manual, IRC5P,
System Overview / Introduction to RobotStudio / The Robot View Explorer.
3HNA010055-001 en Rev.12
63

5.7 Electrical Connection
5.7 Electrical Connection

General
Connections in the manipulator are performed before shipment, and no connection

operation is required by the installer.
Check Connection
The attachment clamps for the manipulator cable may have been disrupted during
handling and transportation of the manipulator. It is for this reason important that
the connection and securing of the cable is checked to prevent faulty operation of
the robot due to noise related to a poorly grounded cable screen etc.
Remove cover on manipulator foot unit (at flexible cable inlet). Inspect connection
and check that the cable screen is firmly secured under the P-clip. If the connection
is not correct, place the cable in correct position and tighten the P-clip as shown in
illustration below. Re-install cover and tighten attachment screw.
Also check that ground cable is connected to clamp beside cable inlet.
Figure 28 Main cable connection in manipulator
Cable clamp
Flexible cable
Cable screen
Manipulator base junction box
Routing Cable
Route manipulator cable via cable conduit etc. and through spray booth wall to
location where purge unit is to be installed.
CAUTION! Cables must be laid in such a manner that they will not be damaged.
Also be aware that going through booth wall may require flame proof passage.
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5.8 Concluding Activities

Description
The manipulator can be installed to operate under many different environmental

conditions and performing different type of operations. Some of these environments
and operations may include use of fluids which can be damaging to the manipulator
or parts of it.
It is for this reason strongly recommended that the manipulator, arm and wrist are
protected as required by applying grease film or other means to avoid damages such
as corrosion of the wrist, solvent entering into the wrist or arm etc. Use of plastic
protection should be avoided.
For more information on this subject, see chapter Preventive Maintenance on
page 67.
3HNA010055-001 en Rev.12
65

66
3HNA010055-001 en Rev.12
6.1 Introduction
6.1 Introduction
About this Chapter
This chapter provides instructions for performing scheduled preventive

maintenance on the manipulator.
The preventive maintenance is based on a maintenance chart with information about
required maintenance activities including intervals, and references to procedures for
the activities.
Note that the intervals described are recommended intervals. The intervals needed
for your installation may vary, depending on environmental conditions, number of
working hours etc. The maintenance routines in this description must be seen in
relation to the plants own maintenance routines for the paint equipment.
Safety Information

WARNING! No maintenance work must be performed on the robot before the safety
guidelines in the Safety Manual have been read and understood. Work must only
be performed by skilled personnel with the proper training.
General Considerations
The prime objective of any preventive maintenance program is to ensure maximum

system availability. Each scheduled and properly performed preventive maintenance
activity should assist in realizing this objective. Preventive maintenance that does
not reduce system downtime is unnecessary and costly.
The robot and paint system is designed to be able to work under very demanding
conditions with a minimum of maintenance. Nevertheless, certain routine checks
and preventative maintenance must be carried out at given periodical intervals.
When performing routine maintenance or repair work, a number of precautions
must be kept in mind to avoid introducing additional errors into the system.
Do not perform more than recommended preventive maintenance on equipment
which is working satisfactorily.
Wipe all surfaces clean before starting maintenance procedures.
To avoid unnecessary contamination by dust etc., always clean outside of control
cabinet and manipulator before opening doors and covers.
3HNA010055-001 en Rev.12
67
6.2 Maintenance Chart
6.2 Maintenance Chart

General
Perform operations described in this list.

3
No.
Activity and reference
Interval
General Maintenance on page 69
Daily *1
Testing the Axis Brakes on page 70
500 hours
Lubricate Hollow Wrist on page 71
5,000 hours
Lubricate Balancing Spring Roller on page 72
2,000 hours
Check Oil Level in Gearboxes on page 73
5 years
Sign.
*1 Interval strongly dependent on environmental conditions.
68
3HNA010055-001 en Rev.12
6.3 General Maintenance
6.3 General Maintenance

General
Following points should be checked / attended to as often as required.
Cleaning the
Manipulator
The manipulator base and arm assembly should be cleaned regularly. Wipe all
surfaces clean using a wet lint-free cloth. Solvents may be used but with care.
Strong solvents such as acetone etc. should be avoided. High pressure cleaning
devices may be used in the spray booth, but spraying directly on the manipulator
should be avoided. If the manipulator is protected by a grease film or other means,
replace as required. (Use of plastic protection should be avoided.)
WARNING! To avoid static electricity, always use a wet or moist cloth on non
conductive surfaces such as paint equipment, hoses etc. Do not use a dry cloth.
Clean Hollow Wrist
The hollow wrist must be cleaned as often as required, if necessary every day, to
avoid accumulation of dirt and dust particles. Use a lint-free cloth for cleaning.
When the wrist is clean, a small amount of grease should be added to the wrist
surfaces. This will simplify the next cleaning.
Check Regularly
Following points should be checked as often as required:

Check for oil leaks. If a major oil leak is discovered, call for service personnel.
Check for excessive play in gears. If this develops, call for service assistance.
Check that cables between control cabinet, purge unit and manipulator are not
damaged.
Check Floor Attachment

Screws
Fastening screws and clamps which fasten the manipulator or rail system in position
to the foundation must be kept clean for corrosive fluids such as water, basic
solutions and acid solutions. This to avoid corrosion of security parts. If the
corrosion protection such as zinc coat or paint have been damaged, parts must be
cleaned and covered by anti-corrosive paint.
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69
6.4 Testing the Axis Brakes
6.4 Testing the Axis Brakes

When to test
During operation, the holding brakes of each axis motor wear normally. A test must
be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brake may be checked as detailed below:
1.
Run each manipulator axis to a position where the combined weight of the
manipulator arm and any load is maximized (max. static load).
2.
Switch the motors off.
3.
Check that all axes maintain their positions.

If the manipulator does not change position as the motors are switched off, then
the applied brake torque is adequate. It is also possible to try to move it by hand
to see if there also is a reassuring margin. When applying the emergency stop
on a moving robot, the brakes will help stopping it. Thus it may be subjected to
wear. Therefore, this test can also be repeated during the life cycle of the
manipulator to check that it maintains its capability.
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6.5 Lubricate Hollow Wrist
6.5 Lubricate Hollow Wrist

Location
The hollow wrist is located on the front of the manipulator arm.

Figure 29 Hollow wrist lubrication points
4 5
10
Tools and Items
Kernite K-NATE NLGI-2 grease

Grease pump
Procedure
This procedure provides necessary instructions for lubricating the wrist.

WARNING! Make sure that the robot and associated systems are switched off and
locked in off position before continuing.

1.
Fill a grease pump with Kernite K-NATE NLGI-2 grease.
CAUTION! When lubricating the wrist, a few 'drops' of lubricant (1g) is sufficient at
each grease nipple. Do not insert a larger portion of lubricant, as this may damage
the wrist seals and internal sleeve.
2.
Lubricate grease nipples 1 - 10, one by one, by pressing a very small portion
(1g) of grease into each nipple.
3.
Repeat lubrication after turning each of the axes 4,5,6 by 90, 180 and 270.
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6.6 Lubricate Balancing Spring Roller
6.6 Lubricate Balancing Spring Roller

Location
The balancing spring roller is located in the base as shown in the illustration below.
Figure 30 Balancing spring roller, base right side view
Spring panel
Spring roller gliding surface
Tools and Items

Grease pump
Hand tools
Procedure
The procedure provides necessary instructions for lubricating the balancing spring
roller.
WARNING! Make sure that the robot and associated systems are switched off and
locked in off position before continuing.

WARNING! Pre-loaded springs. Only lubrication must be performed.
72
1.
Remove spring cover on both sides by unscrewing 3 attachment screws.
2.
Using a brush or similar, add a small portion of Kernite K-NATE NLGI-2

grease to surface on which spring roller is moving on both sides.
3.
Re-install covers.
3HNA010055-001 en Rev.12
6.7 Check Oil Level in Gearboxes

Location
The filling plugs are located on the robot as shown in the illustration below.
Figure 31 Location of oil filling plugs
Filling plug axis 4-6 gearbox
Horizontal arm
Filling plug
Axis 2 gearbox
(Axis 3 on opposite side)
Filling plug
Axis 1 gearbox
Description
The gearboxes are lubricated for life with oil which corresponds to 40,000 hours in
operation, if the robot is operating within the specified ambient temperature range
(ref. Manipulator Specifications on page 37).
To check oil level, open filling plugs and check that oil level is as specified. If not,
top up with specified oil type.
For specification of oil type, specified oil level and filling instructions, see:
Replace Oil for Axes 1, 2, 3 on page 106
Replace Oil for Horizontal Arm Gearbox on page 149
3HNA010055-001 en Rev.12
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7 Repair
7.1 Introduction
7 Repair
7.1 Introduction
About this Chapter
This chapter details all repair activities recommended for the manipulator and any
external units of the manipulator.
It is made up of separate procedures, each detailing a specific repair activity. Each
procedure contains all information required to perform the activity, such as required
tools and items.
The procedures are gathered in sections, divided according to the component
location on the robot.
Safety Information

WARNING! No repair work must be performed on the robot before the safety
guidelines in the Safety Manual have been read and understood. Work must only be
performed by skilled personnel with the proper training.
Organization of
Procedures
The procedures are divided into a procedure for removal and a procedure for
installation. At the start of each procedure, a reference list shows information
located other places in the manual than in the procedure. If you want to print out a
procedure, you should also print the information referred to under reference to get
all information you need to perform the repair operation.
The manual describes the type of service work that can be carried out by the
Customers own service staff on site. Certain types of work, requiring special
experience or special aids, are not dealt with in the manual. In such cases, the
defective module or component should be replaced on site. The faulty item should
be sent to your local ABB organization for service.
Replacement Items
Make sure that any replacement items are available before performing any repair
procedures. Use only replacement items listed in the spare parts catalogue.
Purge System
During operation, the manipulator is supplied by compressed air. For this reason,
the robot can not operate unless all covers are in place and properly sealed. Missing
screws will cause air leaks and result in increased air consumption or failure in the
purge system.
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7 Repair
7.1 Introduction
Tools
Most of the repair work on the robot can be performed with normal hand tools. A
few special tools are however required. These tools will be stated in the procedures
where they are needed.
Reference Information
Following reference information is included in the manual:
Mounting Instructions for Bearings on page 186

Mounting Instructions for Seals on page 187
Tightening Torques on page 189
Loctite Specifications on page 191
Safety Instructions for Replacing Oil in Gearboxes on page 192
Oil Type Specifications on page 193
Grease Type Specifications on page 195
Illustration References
Some references to illustrations are placed in brackets ( ) indicating figure number

and position in the figure. Example: (fig.15/3) means figure 15 position 3.
Calibration
Calibration of the robot must be performed after replacing mechanical parts, when a
resolver error has occurred or when the power supply between a measuring board
and resolver has been interrupted etc.
Calibrating the robot means to place the robot arm and wrist in a specific position
and enter resolver data for this position into the control system. To place the arm
and wrist in this position, a calibration fixture must be available.
For description of the calibration function and procedure for entering calibration
data, see Operators Manual, IRC5P.
For information on how to install the calibration fixture, see Calibration Fixture
Installation on page 177.
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7 Repair
7.2 Releasing Axis Brakes

7.2.1 Introduction
General
The axis brakes need to be released in many cases during installation and repair
work to reposition the robot arm. These are situations where the robot is not
powered which means that the normal brake release with the switches on the robot
vertical arm can not be used.
The following describes how the axis brakes can be released by applying power to
connectors directly on the manipulator.
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7 Repair
7.2.2 Brake Release Safety

General
A number of precautions must be taken when releasing the axis brakes. These
precautions are described in the following.
WARNING! The following precautions must always be read before manually
releasing the axis brakes using the methods described in the following. Failure to do
so may result in serious injury or even death.
Stay Clear of the Robot

Arm
Always stay clear of the robot arm and wrist and/or make sure that the arm and wrist
are properly suspended before releasing the axis brakes. Releasing the brakes may
cause the robot arm and wrist to drop or raise, depending on the weight (paint
equipment) installed on the arm and the tool installed on the wrist. Special attention
must also be paid to the wrist if a heavy tool is installed.
Unstable Manipulator
When the manipulator is not fastened to the floor, it is not stable in the whole
working area. When the brakes are released and the robot arm is moved, care must
be taken to prevent the manipulator from tipping over. Not paying attention to this
hazard can cause severe injuries to personnel or equipment.
The manipulator is typically unstable when the arm is extended too much forwards.
Motors May Generate

Power
Make absolutely certain that no personnel is working on the robot or control system
when moving the robot arm by hand. Moving the electric motors will generate
400VAC which will be present in the robot and control system.
Balancing System
Inoperative
Axis brakes must not be released if the balancing system is inoperative unless the
robot arm and wrist are properly suspended.
Explosion Safety
Make absolutely certain that the spray booth is tested to be gas free before bringing
power supply for releasing the brakes into the spray booth.
78
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7 Repair
7.2.3 Manually Releasing Axis Brakes

General
There are different methods available for manually releasing the axis brakes when
the robot is not powered. These methods, together with information on required
power supply etc. will be described in the following.
Power Supply
To release the brakes when the robot is not operative, an external power source must
be available.
Figure 32 Brake release power supply
24 Volt power supply
Burndy connector
Female Burndy pin
type RC16M9
Wires (min. 1.5 mm)
The power supply must be capable of supplying 24 VDC with minimum 5 Ampere.
To connect the power supply to any of the described connectors, the 2 wires fitted
with female pins must be available.
Releasing All Brakes
All axis brakes can be released simultaneously via a connector in the manipulator
foot unit as described in the following.
Figure 33 Brake release in manipulator foot unit
+24VDC
2
1
0 Volt
4
12
X12
1.
Remove foot unit cover.
2.
Locate connector X12 as shown in illustration above.
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7 Repair
WARNING! Read Brake Release Safety on page 78 before continuing.
3.
Connect +24VDC to pin 2 and 0 Volt to pin 4.
4.
The brakes are now released and the robot arm can be freely moved.
The axes can also be released simultaneously via connectors in the control cabinet:
X12 (pin 2, +24V Power brake) on connector bracket ( (Ref. Product Manual,
Control Cabinet IRC5P, Installation and Commissioning / Connections
Overview / Manipulator Connections).
Releasing Individual
Brake via MTB-01
Axis brakes can be released individually using connectors on the MTB-01 board as
described in the following.
For overview of the manipulator axes, see Design Overview on page 18.
Figure 34 Brake release on MTB-01
Motor 4
Motor 6
Motor 2
Motor 7
X9
Motor 1
X9/X5
X1
Motor 3
Motor 5
24
MTB-01
21
0 Volt
+24VDC
X1
Link
Wires (min. 1.5 mm )
Male Burndy pin

type RM16M9
Before starting the following procedure, attach 2 e.a. male burndy pins to a wire to
make a proper link as shown in the illustration above.
CAUTION! Make sure that a proper link is used, do not simply press two Burndy
pins together between the fingers.
WARNING! As you need to stand close to the robot arm when releasing the axis
brakes as described in this procedure, extreme care must be exercised, especially

when releasing brakes for axes 2 and 3. Always stand beside the arm and/or suspend
the arm before releasing the brakes for the mentioned axes.
80
1.
Remove vertical arm front cover.
2.
Locate MTB-01 board attached inside arm.
3HNA010055-001 en Rev.12
7 Repair
3.
Locate connectors X1 and X9 on the board.
Releasing Individual
Brake Directly on Motor
4.
Connect +24VDC to pin 2 and 0 Volt to pin 4 in connector X1.
5.
To release brake for a certain axis, link pin for required motor with pin 12 in
connector X9, e.g. link pin 12 - 6 to release brakes for motor 4.
6.
The brake for the selected axis is now released and the axis can be freely
moved.
Axis brakes can be released individually by applying power directly in the motor
connector as described in the following.
For overview of the manipulator axes, see Design Overview on page 18.
Figure 35 Brake release on axis motor
Connector on motors
3
9
1
8
+24VDC
0 Volt
Motor connector axis 1 - 7
1.
Locate axis motor and remove cover to get access to the motor.
2.
Disconnect motor connector.
3.
Connect +24VDC to pin 7 and 0 Volt to pin 8 in connector for required motor.
4.
The brake for the selected axis is now released and the axis can be freely
moved.
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7 Repair
82
3HNA010055-001 en Rev.12
7 Repair

General
The following procedures provide information for replacing components on the

base unit for the IRB 580 robots.
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83
7 Repair
7.3.1 Removal of Motor for Axis 1, 2, 3

Location
The motors for axis 1,2,3 are located in the base unit as shown in the figure below.
Figure 36 Base unit, right side view
Front
4
3
2
1
Axis 3 motor, base unit rear view

7
8
6
9
10
11
84
Axis motor 1
Axis motor 2
Axis motor 3
Rear cover
Front cover
Motor attachment nuts
Motor connector
Connector bracket
Motor shaft
10
Measuring system receptacle
11
Measuring system connector
3HNA010055-001 en Rev.12
7 Repair
References
Releasing Axis Brakes on page 77

Tools and Items
Hand tools
Procedure
The procedure describes how to remove the motors for axis 1, 2, 3.

Note: The following guidelines are for axis 3 motor removal (left side motor - rear
view). Axis 2 motor removal (right side motor - rear view) and axis 1 motor
removal guidelines are identical unless specifically noted.
regulations in Safety on page 13 have been read and understood.

1.
Prepare operation.
a.
Release axis brakes. Ref. Releasing Axis Brakes on page 77.
b.
Check the balancing of the arm. If necessary, arm must be suspended

before removing the motor for axis 2 or 3 (depending on weight installed
on arm and balancing spring adjustment etc.)
c.
Activate brakes.
d.
Turn the electrical disconnect switch off and lock switch in off position.
WARNING! Make sure that the mains switch is off and locked in off position
before continuing. Also make sure that possible other connected systems are off.
2.
e.
Remove oil from gearbox for axis 3 (axis 2: Remove oil from gearbox for
axis 2). Refer to Replace Oil for Axes 1, 2, 3 on page 106 for
information. For axis 1, it is not necessary to remove oil from gearbox.
f.
Remove base rear cover (fig.36/4) to get access to motor for axis 3 and 1.
For axis 2, remove front cover (fig.36/5).
Disconnect electrical connections.

a.
Disconnect motor connector (fig.36/7).
b.
Disconnect measuring system connector (fig.36/11) and remove receptacle

(fig.36/10) from bracket.
c.
Remove 2 screws securing connector bracket to motor (fig.36/8). (Axis 1

and 3: only 1 screw is used to secure bracket).
d.
Move connector bracket aside.

For axis 2, remove 2 attachment screws for measuring system board and
move board aside to give better access to motor.
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7 Repair
WARNING! If arm is not fully balanced, arm must be supported before continuing.
3.
Remove motor.
a.
Note position of motor before removing it so that you will be able to install
new motor in same position.
b.
Remove 4 e.a. attachment nuts (fig.36/6) securing motor to base unit

frame. Retain nuts for use with new motor.
c.
Remove motor.
WARNING! Axis brake has no function when a motor is removed (arm is free).
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7 Repair
7.3.2 Installation of Motor for Axis 1, 2, 3

Location
The motors for axis 1,2,3 shall be installed in the base unit as shown in the figure
below.
Figure 37 Base unit, right side view
Front
4
3
2
1
Axis 3 motor, base unit rear view

7
8
6
9
10
11
Axis motor 1
Axis motor 2
Axis motor 3
Rear cover
Front cover
Motor attachment nuts
Motor connector
Connector bracket
Motor shaft
10
Measuring system receptacle
11
Measuring system connector
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7 Repair
References

Tools and Items
Hand tools
Rotor rotating tool
Procedure
The procedure describes how to install the motors for axis 1, 2, 3.

Note: The following guidelines are for axis 3 motor installation (left side motor rear view). Axis 2 motor installation (right side motor - rear view) and axis 1 motor
installation guidelines are identical unless specifically noted.

1.
Prepare operation.
2.
3.
88
a.
Clean mounting surface on motor flange and base unit using a lint-free
cloth.
b.
Check that motor flange and mounting surface on base are not scratched or
damaged.
c.
Make sure that the o-ring is properly positioned in the groove. Add 4 spots
of Kernite K-NATE NLGI-2 grease pitched 90 in the groove to keep oring in position.
Install motor.
a.
Move motor into position in base unit. Make sure that it is positioned in the
same way as the motor which was removed.
b.
Install motor attachment nuts (fig.37/6) and tighten lightly (2 Nm torque).
Adjust motor.
a.
Insert screw of rotor rotating tool on rear of motor shaft (fig.37/9). Rotate
tool until it stops. Tighten lightly.
b.
The motor has a little play between the motor brake and the rotor. Move
the tool lightly from side to side to make yourself familiar with the play in
the brake.
c.
Release axis brakes for motor. Ref. Releasing Axis Brakes on page 77.
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7 Repair
d.
Using a plastic hammer, knock lightly on the motor on the side facing
away from the gear. For axis 2 and 3, the point is at the lower front, and for
axis 1 the point is on the side facing the corner of the base unit.
e.
Use a combination of turning the rotor using the tool and move the robot
horizontal arm up / down by hand (axis 2: Move vertical arm forwards /
backwards, axis 1: Move arm sideways) to find the position where the play
between the gear of the motor and gearbox is the smallest.
Note: Finding the correct adjustment is not easy, and several tests should
be performed to be as sure as possible that the adjustment is good enough.

Too tight, or too loose grip in the gear may cause unnecessary wear.
4.
5.
f.
When adjustment is as required, cross-tighten motor attachment nuts.
g.
As a final check, rotate rotor and move arm to feel that rotation is not too
tight or loose over the full area of the motion of the robot arm.
h.
Activate axis brakes.
i.
Remove rotor rotating tool.
j.
For axis 2 motor, put measuring system board back in place and secure
attachment screws.
Perform motor connections.

a.
Insert measuring system receptacle (fig.37/10) into bracket and secure.
b.
Connect measuring system connector (fig.37/11) and motor connector

(fig.37/7).
c.
Install connector bracket and secure attachment screws.
Refill oil.
a.
6.
Refill oil in gearbox. Refer to Replace Oil for Axes 1, 2, 3 on page 106
for information.
Conclude operation.
a.
Install cover.
b.
Calibrate the robot. For information, see Calibration Fixture Installation

on page 177.
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7 Repair
7.3.3 Removal of Axis 1 Shaft Seal

Location
The axis 1 shaft seal is located in the base unit as shown in the figure below.
Figure 38 Base unit, left side view
4
Lifting position
8
Base unit
1
2
Foot unit
3
5
1
Support ring
Support ring attachment screws
Seal
Cable hose attachment screws
Foot unit bottom cover
Foot unit bottom cover attachment screws
Axis 1 shaft attachment screw
Front- and rear cover
References

Tools and Items
Hand tools
Procedure
The procedure describes how to remove axis 1 shaft seal.

1.
Prepare operation.
a.
90
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7 Repair
b.
Move arm to a stable lifting position (shown in Figure 38).
c.
Activate brakes.
d.
e.
2.
Remove oil from gearbox for axis 1. Refer to Replace Oil for Axes 1, 2, 3
on page 106 for information.
Disconnect cables.
Note: Before disconnecting any connectors, ground wires or cable straps,
carefully note position to ensure correct reinstallation.
3.
a.
Remove base unit front- and rear cover (fig.38/8).
b.
Disconnect relevant 4 sockets, cable clamps and ground wire in base unit
rear side. The sockets are installed on a bracket. To remove them, first
disconnect the corresponding connector.
c.
Disconnect relevant 2 connectors, socket, cable coupling connector and

cable clamps in base unit front side. The socket is installed on a bracket. To
remove it, first disconnect the corresponding connector.
d.
Remove screws (fig.38/4) on top of base unit securing cable hose to base
unit (2 outer screws, using a 5 mm hexagonal key).
Split base unit and foot unit.

a.
Attach lifting straps to robot and lift high enough (approx. 1 meter) to get
access to underside of foot unit. For information on how to lift the robot,
see Lifting and Transporting the Manipulator on page 52.
WARNING! Do not walk under the hanging load.
b.
Remove screws (fig.38/6) securing cover (fig.38/5) to underside of foot

unit. Remove cover. Retain screws and cover for reinstallation.
c.
Place a support under the robot.
CAUTION! The support must be arranged in such a way that the robot (and later the
foot unit) will be stable and at the same time access is provided to the center of the
underside of the foot unit. Weight of foot unit is approx. 150 kg.
d.
Lower the robot down on the support. Keep lifting straps tense.
e.
Unscrew screws (fig.38/7) securing axis 1 shaft to foot unit. Retain screws
for reinstallation.
f.
Lift the robot carefully from the foot unit while guiding the cables out from
the axis 1 shaft center. Be careful not to damage the cable assembly.
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7 Repair
4.
92
Remove old shaft seal.

a.
Locate seal support ring on underside of base unit. Unscrew support ring
attachment screws (fig.38/2) and remove ring (fig.38/1) for easier access to
seal.
b.
Remove old seal (fig.38/3) using a screwdriver or similar tool. Be careful

not to damage shaft during this operation.
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7 Repair
7.3.4 Installation of Axis 1 Shaft Seal

Location
The axis 1 shaft seal shall be installed in the base unit as shown in the figure below.
Figure 39 Base unit, left side view
4
Lifting position
8
Base unit
1
2
Foot unit
3
5
1
Support ring
Support ring attachment screws
Seal
Foot unit bottom cover
Foot unit bottom cover attachment screws
Axis 1 shaft attachment screw
Front- and rear cover
References

Tools and Items
Hand tools
Procedure
The procedure describes how to install axis 1 shaft seal.

1.
Prepare operation.
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7 Repair
2.
3.
4.
a.
Clean axis 1 shaft using a lint-free cloth.
b.
Check that the shaft is undamaged and has no scratches.
Install seal.
a.
Check that the new seal is not damaged.
b.
Press new seal (fig.39/3) into position on the shaft.
c.
Slide seal support ring (fig.39/1) into position and secure attachment
screws (fig.39/2).
Attach foot unit.

a.
Lower the robot into position on the foot unit. Make sure to guide the cable
harness into correct position during the lowering process.
b.
Install axis 1 shaft attachment screws (fig.39/7). Tighten screws.
c.
Clean foot unit bottom cover (fig.39/5) and mounting surface on foot unit
for remains of old liquid gasket.
d.
Lay a new string of liquid gasket on the bottom plate.
e.
Install foot unit bottom cover. Tighten screws.
f.
Lift the robot a little and remove support.
g.
Lower the robot down to the floor. Remove lifting straps.
Install connections.
Note: All connections must be made according to markings on connectors and
notes made during removal.
5.
94
a.
Install 4 sockets, cable clamps and ground wire in base unit rear side.
Remember to install the corresponding connectors to the newly installed
sockets.
b.
Install 2 connectors, socket, cable coupling connector and cable clamp in

base unit front side. Remember to connect the corresponding connector to
the newly installed socket.
c.
Install 2 attachment screws on top of the base unit.
d.
Install cover on base unit front- and rear cover.
Conclude operation.
a.
Refill oil in gearbox for axis 1. Refer to Replace Oil for Axes 1, 2, 3 on
page 106 for information.
b.

on page 177.
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7 Repair
7.3.5 Disengage Balancing Spring

Description
The balancing springs are used to counter balance the vertical and horizontal arm
when the axes brakes are released.
Location
The balancing springs are located, one on each side, in the base unit as shown in the
figure below.
Figure 40 Balancing spring axes 2 and 3
9
Rear view
4
Spring compression direction
Compression screw
Bearing spring top clearance
Spring bottom surface
Spring compression access hole
Balancing spring axis 2
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7 Repair
Balancing spring cover axis 2
References
Tools and Items
Hand tools
Procedure
The procedure describes how to disengage the balancing springs.

Note: The following guidelines are for axis 2 balancing spring (right side - rear
view). Axis 3 balancing spring (left side - rear view) removal procedure is identical
unless specifically noted. Note that the horizontal arm is balanced via the parallel
rod at the back of the vertical arm.

1.
Prepare operation.
a.
b.
2.
Remove right side spring cover (fig.40/8) to get access to spring assembly
(Axis 3 spring: Remove left side spring cover (fig.40/9).
Compress spring.
a.
b.
Compress spring (fig.40/1) by moving vertical arm forwards (or

backwards) (Axis 3: Move horizontal arm down).
Note: How to compress the spring depends on the reason for compressing
the spring. If the reason is to replace the spring, the spring must be fully
compressed. If the reason is to replace a component such as the vertical
arm, etc., the spring may not need to be compressed more than required for
the job.
c.
3.
96
Verify that spring is compressed.
Disengage spring.
a.
Remove spring compression screw (fig.40/2) from suspension beside

spring.
b.
Insert spring compression screw in hole (fig.40/5) on underside of spring

assembly.
3HNA010055-001 en Rev.12
7 Repair
c.
Tighten screw until it hits the bottom surface (fig.40/4) of the spring
assembly.
d.
Move vertical arm to center position (Axis 3: Move horizontal arm to

horizontal position) to transfer spring force from crankshaft to spring
attachment screw.
e.
Activate axis brakes. Suspend or support robot arm as required.
f.
Check visually that there is clearance (fig.40/3) between the crankshaft

bearing and top of spring assembly. This indicates that the spring force has
been removed from the arm.
WARNING! The robot arm is not balanced when the balancing is disengaged. To
prevent hazardous situations, mark brake release function to prevent accidental

releasing of the axis brakes. Additionally the robot arm needs to be suspended or
supported, because the axis brakes are not always able to prevent the arm from
sagging, especially when additional equipment is mounted on the arm.
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7 Repair
7.3.6 Engage Balancing Spring

Location
figure below.
9
Rear view
4
98
Spring compression direction
Compression screw
Bearing spring top clearance
Spring bottom surface
Spring compression access hole
3HNA010055-001 en Rev.12
4
7 Repair
References
Tools and Items
Hand tools
Procedure
The procedure describes how to engage the balancing springs.

unless specifically noted.

1.
Prepare operation.
a.
WARNING! Releasing axis brakes when spring is disengaged will cause the robot
arm to drop rapidly if arm is not supported.

b.
Make sure the arm is properly supported and release axis brakes. Ref.
c.
Move vertical arm forwards or backwards (axis 3: move horizontal arm

downwards) to transfer spring force from spring compression screw to
crankshaft. Check alignment of the crankshaft bearing (track roller) and
the rail on top of spring assembly. If required bend the spring unit to fit the
roller on the rail.
Note: Avoid alignment with high spring force.
d.
2.
3.
Activate brakes.
Engage spring.
a.
Check visually that there is clearance between the spring compression

screw and the bottom surface of the spring assembly.
b.
Remove spring compression screw.
c.
Install spring compression screw in suspension.
Conclude operation.
a.
Release axis brakes and move horizontal arm or vertical arm to center
position as required.
b.
Re-install spring cover.
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7 Repair
7.3.7 Removal of Balancing Spring

Location
figure below.
9
Rear view
5
4
100
Crank shaft gliding surface
Spring extension attachment screw
Spring extension
Spring assembly attachment screw
Axis 3 spring extension
3HNA010055-001 en Rev.12
7 Repair
References
Disengage Balancing Spring on page 95
Tools and Items
Hand tools
Procedure
The procedure describes how to remove the balancing springs.

unless specifically noted.

1.
Prepare operation.
a.
b.
Transfer balancing spring force from robot arm to spring as described in

procedure Disengage Balancing Spring on page 95.
WARNING! The balancing spring removed from the robot, and the replacement
spring are under a considerable tension and form a potential hazard. Rough
handling, dropping etc. of the spring must be avoided.
2.
Remove spring.
a.
Remove 2 screws (fig.42/2) on top of spring securing spring extension to

spring assembly.
b.
Remove extension (fig.42/3). Retain extension and attachment screws for

installation on new spring.
c.
Unscrew 4 spring assembly attachment screws (fig.42/4). Note that axis 3

spring has an extension (fig.42/5) between the spring and the base unit on
one side. Retain this extension for installation with the new spring
d.
Remove complete spring assembly.

Note: The spring assembly includes one guide pin on each side and you
may have to move backwards and forwards or jiggle it around to loosen
assembly.
WARNING! Do not try to disassemble spring unit. The complete spring assembly
must be handled as one unit.
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7.3.8 Installation of Balancing Spring

Location
The balancing springs shall be installed, one on each side, in the base unit as shown
in the figure below.
9
Rear view
5
4
102
Crank shaft gliding surface
Spring extension attachment screw
Spring extension
Spring assembly attachment screw
Axis 3 spring extension
3HNA010055-001 en Rev.12
7 Repair
References
Engage Balancing Spring on page 98

Adjusting Balancing Spring Tension on page 104
Tools and Items

Hand tools
Procedure
The procedure describes how to install the balancing springs.

view). Axis 3 balancing spring (left side - rear view) installation procedure is
identical unless specifically noted.

1.
Prepare operation.
2.
3.
Install new spring.

a.
Place new spring in position on guide pins and carefully knock spring
assembly into position using a plastic hammer. (Axis 3: Place extension
(fig.43/5) in position).
b.
Tighten 4 attachment screws (fig.43/4).
c.
Place spring extension (fig.43/3) on top of spring assembly. Install 2

attachment screws (fig.43/2) and tighten.
d.
Add Kernite K-NATE NLGI-2 grease to crankshaft gliding surface

(fig.43/1).
Conclude operation.
a.
Transfer spring tension back to robot arm as described in procedure in

Engage Balancing Spring on page 98.
b.
Check balancing of robot arm. If balancing is not as required, adjust spring

tension as described in procedure in Adjusting Balancing Spring Tension
on page 104.
c.
Re-install spring cover.
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7.3.9 Adjusting Balancing Spring Tension

Location
figure below.
Figure 44 Balancing springs axes 2 and 3
9
Rear view
Increase force
Increase force
Reduce force
1
5
2
4
4
Reduce
force
104
Roller attachment screw
Roller
Lever arm
Spring - roller clearance
Roller adjustment
3HNA010055-001 en Rev.12
7 Repair
References

Tools and Items
Hand tools
Procedure
The procedure describes how to adjust the balancing spring tension.

view). Axis 3 balancing spring (left side - rear view) procedure is identical unless
specifically noted.

1.
Before the spring force can be adjusted, the spring must be compressed as
described in procedure Disengage Balancing Spring on page 95.
WARNING! No adjustment must be attempted unless the spring has been secured.
2.
When spring has been locked in position (secured), check that there is clearance
(fig.44/4) between top of spring and roller. Loosen 2 screws (fig.44/1) securing
roller (fig.44/2) to lever arm (fig.44/3).
3.
Change balancing spring force by adjusting offset of roller (fig.44/5) away

from center to increase force or closer to center to reduce force.
Optimal adjustment of the balancing is obtained when the arm is not falling or
raising in any position. If payload is increased, a new adjustment of the
balancing is required.
4.
Tighten screws (fig.44/1).
5.
Transfer spring force back to robot arm as described in procedure Engage

Balancing Spring on page 98.
6.
Check that balancing is as required. If not, repeat operation from Step 1.
CAUTION! Move vertical arm and horizontal arm to extreme positions and check
that the springs do not get fully compressed before the axis reaches the end of the
movement. Should this occur, repeat procedure and reduce spring force accordingly.
7.
When finished, re-install spring covers.
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7.3.10 Replace Oil for Axes 1, 2, 3

Location
The drain- and filling plugs are location on the base unit as shown in the figure
below.
Figure 45 Location of oil plugs axes 1, 2, 3
Breathing plug axis 2 gearbox

Filling plug axis 2 gearbox
Filling plug
axis 1 gearbox
Drain plug axis 2 gearbox
References
Tools and Items
Hand tools
Pump, hose and container
Oil Specification
Oil type:
Mobil MobilgearTM 600 XP 320
Quantity:
Axis 1: 3 liter
Axis 2-3: 5.4 liter
Level:
All axes, 0-20 mm below filling hole
Note: Oil quantity refers to an empty, clean gearbox. Later refilling will require a
lower quantity.
Procedure
The procedure describes how to replace oil in gearboxes for axes 1, 2 and 3.

106
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7 Repair
WARNING! Before starting to replace oil, observe Safety Instructions for
Replacing Oil in Gearboxes on page 192.

1.
Remove oil.
a.
Place a tray or similar under the drain plug for required axis.
b.
Remove drain plug for required axis.

Note: Axis 1 uses a common filling and drain plug. For this reason, the oil
must be pumped out for this axis using a suitable pump and hose.
2.
Fill new oil.

a.
Clean drain plug. Re-install plug and tighten. For axis 1, do not install plug
at this stage.
b.
Remove filling plug.
c.
Fill gearbox with Mobil MobilgearTM 600 XP 320 until oil level is as
specified, see Oil Specification on page 106.
d.
Clean plug. Re-install plug and tighten.
Note: Oil drained from the manipulator must be disposed of in accordance with
local regulations.
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108
3HNA010055-001 en Rev.12
7 Repair

General

vertical arm for the IRB 580 robots.
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7.4.1 Removal of Vertical Arm

Location
The vertical arm is located on the robot as shown in the figure below.
Figure 46 Vertical arm, right side view
5
6
Drive shaft attachment screws
Support plate attachment screws
Support plate clamp screw
Support plate
Vertical arm
Front cover
Vertical arm lower end, front view
References

Removal of Horizontal Arm on page 126
Tools and Items
Hand tools
Procedure
The procedure describes how to remove the vertical arm.
110
3HNA010055-001 en Rev.12
7 Repair

1.
Prepare operation.
a.
Disengage balancing spring tension for axis 2 and axis 3 springs. Refer to
procedure in Disengage Balancing Spring on page 95.
WARNING! Axis brakes must not be released from this point on unless the robot
arm is supported as releasing the brakes will cause the robot arm to drop.
b.
2.
3.
Disconnect upper cables, leading to horizontal arm.

a.
Remove vertical arm front cover (fig.46/6).
b.
Disconnect all connectors for the cable leading out from the top of the
vertical arm. Note position of connectors to ensure correct re-connection
during installation of new arm.
c.
Remove 2 e.a. screws securing cable attachment to top of vertical arm

using a 10 mm pipe wrench.
d.
Pull cables upwards out of arm.
Remove horizontal arm.

a.
4.
5.
Remove horizontal arm as described in procedure Removal of Horizontal

Arm on page 126.
Disconnect lower cables.

a.
Disconnect all connectors and ground connections for the 2 cables leading
up from the bottom of the vertical arm. Note position of connectors to
ensure correct re-connection during installation of new arm.
b.
Remove 2 e.a. screws securing cable attachment to bottom of vertical arm

using a 10 mm pipe wrench.
c.
Pull cables downwards out of arm.
Remove vertical arm.

a.
Remove 7 e.a. screws (fig.46/2), securing vertical arm to vertical arm

support plate (fig.46/4). Retain screws for installation on new arm.
b.
Loosen (do not remove) clamp screw (fig.46/3), clamping vertical arm
support plate to vertical arm support bearing.
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c.
Suspend vertical arm with strap and lifting device before continuing. The
weight of the arm is approximately 25 kg.
WARNING! Performing the next step will cause the arm to fall if not properly
suspended.
112
d.
Remove 12 e.a. screws (fig.46/1) securing vertical arm to vertical arm

drive shaft. Retain screws for installation on new arm.
e.
Note position of arm to ensure that the new arm is installed in the same
position.
f.
Lift out vertical arm.
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7 Repair
7.4.2 Installation of Vertical Arm

Location
The vertical arm shall be installed on the robot as shown in the figure below.
5
6
Drive shaft attachment screws
Support plate attachment screws
Support plate
Vertical arm
Front cover
References
Installation of Horizontal Arm on page 130 for IRB 580

Tools and Items
Hand tools
Loctite 243 glue (blue)
Procedure
The procedure describes how to install the vertical arm.
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7 Repair

1.
Prepare operation.
2.
3.
4.
5.
114
Install vertical arm.

a.
Lift vertical arm into position.
b.
Make sure that arm is placed in the same position as the old arm.
c.
Secure vertical arm to vertical arm drive shaft with 12 e.a. screws
(fig.47/1).
d.
Secure other side of arm to vertical arm support plate using 7 e.a. screws
(fig.47/2). Move support plate as required to engage screws.
e.
Tighten vertical arm support plate clamp screw (fig.47/3) with 2 Nm

torque. Use Loctite 243 glue (blue).
Install horizontal arm.

a.
Install horizontal arm as described in procedure Installation of Horizontal

Arm on page 130.
b.
Engage balancing springs for axis 2 and axis 3 as described in procedure

Engage Balancing Spring on page 98.
Install electrical connections.

a.
Enter cables from base unit and horizontal arm into vertical arm.
b.
Install 2 e.a. screws securing cable attachment to bottom and top of vertical
arm using a 10 mm pipe wrench.
c.
Insert connectors and connect ground connections for the cables.
Conclude operation.
a.
Install vertical arm front cover.
b.

on page 177.
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7 Repair
7.4.3 Removal of Vertical Arm Lower Bearing

Location
The vertical arm is located on the robot as shown in the figure below.
Upper joint
Rear view
1
2
3
1
Upper joint bracket
Upper joint bracket attachment screws
Parallel rod lever arm support screws
Parallel rod lever arm
References
No References
Tools and Items
Hand tools
Procedure
The procedure describes how to remove the vertical arm lower bearing.
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1.
Prepare operation.
a.
Place the vertical arm in vertical position and the horizontal arm in
horizontal position.
Important: Make sure that the position of the vertical arm is not altered during the
replacement operation.
b.
Suspend horizontal arm.
c.
2.
Disconnect parallel rod upper attachment.
WARNING! Performing the next step will cause the horizontal arm to fall if not
properly suspended.
a.
Unscrew 2 screws (fig.48/2) for upper joint brackets (fig.48/1) on each side
of the upper parallel rod attachment.
b.
Lay down the parallel rod.
WARNING! Axis brakes must under no circumstances be released when the parallel
rod is in this position as this will cause the parallel rod to strike violently upwards. If
the robot is left for a period of time without removing the rod, tie the rod so that it is
resting parallel with the vertical arm.
3.
4.
116
Remove Bearing
a.
Loosen support plate clamp screw (fig.48/6). Do not remove screw.
b.
Remove 12 screws (fig.48/3) securing parallel rod lever arm (fig.48/4) to

vertical arm.
c.
Pull lever arm / parallel rod assembly out.
Remove old bearing.

a.
Take lever arm / parallel rod assembly to a work bench.
b.
Remove bearing from assembly using a plastic hammer or other suitable

tool.
c.
Discard old bearing.
3HNA010055-001 en Rev.12
7 Repair
7.4.4 Installation of Vertical Arm Lower Bearing

Location
The vertical arm shall be installed on the robot as shown in the figure below.
Upper joint
Rear view
1
2
3
1
Upper joint bracket
Upper joint bracket attachment screws
Parallel rod lever arm support screws
Parallel rod lever arm
References
No references
Tools and Items
Hand tools
3HNA010055-001 en Rev.12
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7 Repair
Procedure
The procedure describes how to install the vertical arm lower bearing.

1.
Prepare operation.
2.
3.
4.
118
Install bearing in bearing bracket.

a.
Place new bearing in position in lever arm / parallel rod assembly.
b.
Press bearing into position.
Install lever arm / parallel rod assembly.

a.
Place lever arm / parallel rod assembly in position on vertical arm.
b.
Press assembly into position.
c.
Install 12 attachment screws. Cross tighten screws.
d.
Tighten vertical arm support plate clamp screw (fig.49/5) with 2 Nm

torque. Use Loctite 243 glue (blue).
Conclude operation.
a.
Place parallel rod in position and install upper brackets.
b.

on page 177.
3HNA010055-001 en Rev.12
7 Repair
7.4.5 Removal of Bearings in Parallel Rod

Location
The parallel rod is located at the rear of the vertical arm as shown in the figure
below.
Figure 50 Vertical arm and parallel rod, rear view
Upper joint
Upper bearing
Lower bearing
Upper joint attachment screws
Bearing cover plate
Lock nut
Lock ring
Circlip
Grease nipple
Parallel rod
References
No references
Tools and Items
KM5 pipe wrench
3HNA010055-001 en Rev.12
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7 Repair
Procedure
Circlip pliers
Small puller (may not be required)
Hand tools
The procedure describes how to remove the bearings in the parallel rod.
Note: The following guidelines are for the lower bearing removal. Upper bearing
removal guidelines are identical unless specifically noted.


1.
Prepare operation.
a.
b.
2.
Suspend horizontal arm.
Disconnect parallel rod from horizontal arm.
WARNING! Performing next step will cause the horizontal arm to drop if arm has
not been suspended.

a.
Unscrew 2 screws (fig.50/1) for brackets on each side of the upper parallel
rod attachment.
b.
Lay down the parallel rod.
WARNING! Axis brakes must under no circumstances be released when the parallel
rod is in this position as this will cause the parallel rod to strike violently upwards. If
the robot is left for a period of time without removing the rod, tie the rod so that it is
resting parallel with the vertical arm.
3.
120
Remove bearing from shaft.

a.
Insert medium size screwdriver under cover plate (fig.50/2) for bearing.
Bend carefully using the screwdriver to remove cover.
b.
Open lip on lock ring (fig.50/4) to free lock nut.
c.
Unscrew lock nut (fig.50/3) using a KM5 pipe wrench.
d.
Install a grease nipple (fig.50/6) in center of shaft. (Upper bearing:

Remove hex screw before installing grease nipple).
e.
Press Kernite K-NATE NLGI-2 grease into nipple to try to free bearing
from cone on shaft.
3HNA010055-001 en Rev.12
7 Repair
f.
4.
Using a plastic hammer, carefully knock on the bearing housing to free

bearing. (Upper bearing: Knock on shaft). If this will not free bearing, use
puller combined with careful knocking to remove parallel rod from shaft.
Remove bearing.
a.
Remove circlip (fig.50/5) for bearing.
b.
Carefully knock out bearing using a plastic hammer.
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7.4.6 Installation of Bearings in Parallel Rod

Location
The parallel rod shall be installed at the rear of the vertical arm as shown in the
figure below.
Figure 51 Vertical arm and parallel rod, rear view
Upper joint
Upper bearing
Lower bearing
Upper joint attachment screws
Bearing cover plate
Lock nut
Lock ring
Circlip
Grease nipple
Parallel rod
References
No references
Tools and Items
Hand tools
122
3HNA010055-001 en Rev.12
7 Repair
Procedure
The procedure describes how to install the bearings in the parallel rod.
Note: The following guidelines are for the lower bearing installation. Upper bearing
installation guidelines are identical unless specifically noted.


1.
Prepare operation.
2.
3.
Install new bearing.

a.
Insert new bearing in bearing housing.
b.
Insert circlip (fig.51/5).
Install parallel rod.

a.
Enter bearing housing on shaft. (Upper bearing: Insert shaft into bearing
from the left side, rear view).
b.
Insert lock ring (fig.51/4).
c.
Install lock nut (fig.51/3). Tighten nut while twisting parallel rod from side
to side. Tighten until a small friction can be felt. (Upper bearing: Twist
shaft from side to side).
CAUTION! Do not tighten too hard as this will cause unnecessary wear of the
bearing.
4.
d.
Lock nut with lock ring.
e.
Install cover (fig.51/2).
Conclude operation.
a.
Place parallel rod in position and install upper brackets (fig.51/1).
Note: If a new parallel rod has been installed it will be required to calibrate the
robot as the new parallel rod may not be of the exactly same length as the old
rod. For calibration information, see Calibration Fixture Installation on
page 177.
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124
3HNA010055-001 en Rev.12
7 Repair

General

horizontal arm for the IRB 580 robots.
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7.5.1 Removal of Horizontal Arm

The horizontal arm is located on top of the vertical arm as shown in the figure
below.
Location
Figure 52 Horizontal arm, robot right side view

1
2
3
1
10
11
12
13
126
Horizontal arm rear cover
Parallel rod attachment screws
Cap attachment screws
Cap
Screw for extracting bearing support
Bearing support attachment screws
Bearing support
Motor power connectors
3HNA010055-001 en Rev.12
7 Repair
10
Purge connector
11
Measuring system connectors
12
Ground connection
13
Purge sensor
References

Tools and Items
Hand tools
Procedure
The procedure describes how to remove the horizontal arm.

Note: The following guidelines describe the removal of the horizontal arm for
replacement or repair purposes. Guidelines for removing the horizontal arm
temporarily for replacement of the vertical arm are identical unless specifically
noted.

1.
Prepare operation.
Note: If the horizontal arm is to be removed temporarily for replacement of
vertical arm, the balancing springs will already have been disengaged and the
cables will have been disconnected in the vertical arm. If this is the case,
continue to Step 3.
a.
Disengage balancing spring tension for axis 3 spring. Refer to procedure in

Disengage Balancing Spring on page 95.
b.
c.
Open horizontal arm rear cover (fig.52/1) and disconnect purge sensor
connector from purge sensor. The purge sensor (fig.52/13) is installed in
the horizontal arm rear cover. Remove horizontal arm rear cover.
Note: If the robot is non-ex version, purge sensor is not installed. In this
case, remove dummy connector from purge sensor connector and retain for
installation on new arm.
2.
Remove connections for horizontal arm.
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3.
a.
Disconnect 3 e.a. connectors (fig.52/9) for motor power for motor 4, 5 and
6.
b.
Disconnect 3 e.a. connectors (fig.52/11) for measuring system for motor 4,

5 and 6.
c.
Disconnect ground connection (fig.52/12).
d.
Remove cable straps.
e.
Loosen 2 e.a. cable hose attachment screws (fig.52/8) and pull out the 2
cables. The attachment is located on the underside of the arm.
Disconnect parallel rod.

a.
Make sure that arm is properly suspended.
WARNING! Performing the next steps will cause the horizontal arm to drop if not
suspended.
4.
b.
Unscrew 2 e.a. screws (fig.52/2) for brackets on each side of the upper
parallel rod attachment.
c.
Remove brackets. Retain brackets and screws for installation on new arm.
d.
Lay down parallel rod. If required, first release axis brakes for axis 3 and
move horizontal arm a little downwards. Ref.: Releasing Axis Brakes on
page 77.
Remove horizontal arm.

a.
Remove 4 e.a. screws (fig.52/3) for cap (fig.52/4) on both sides of the
horizontal arm/vertical arm joint.
b.
Remove caps. Retain caps and screws for re-installation.
c.
Unscrew 4 e.a. M8 screws (fig.52/6) for bearing support (fig.52/7) on both

sides.
d.
Install one of the removed M8 screws (fig.52/5) in hole in center of bearing

support.
e.
Suspend horizontal arm with strap and lifting device before continuing.
The weight of the arm is 40-45 kg.
WARNING! Performing the next step will cause the arm to fall if not properly
suspended.
128
f.
Using the screw installed in center of the bearing support as puller, pull out
bearing support (fig.52/7) on each side 6-7 mm to free horizontal arm.
g.
Remove complete horizontal arm.
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7 Repair
Note: If the horizontal arm is removed for replacement of the vertical arm,
remove bearing supports and retain for installation on new vertical arm.
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7.5.2 Installation of Horizontal Arm

The horizontal arm shall be installed on the top of the vertical arm as shown in the
figure below.
Location
Figure 53 Horizontal arm, robot right side view

1
2
3
1
10
11
12
13
130
Parallel rod attachment screws
Cap attachment screws
Cap
Screw for extracting bearing support
Bearing support attachment screws
Bearing support
3HNA010055-001 en Rev.12
7 Repair
10
Purge connector
11
12
Ground connection
13
Purge sensor
References
Tools and Items
Hand tools
Procedure
The procedure describes how to install the horizontal arm.


1.
Prepare operation.
a.
Check that bearing supports (fig.53/7) on both sides are installed but not
fully inserted so that the horizontal arm can be lifted into position between
supports.
Note: If the vertical arm has been replaced, install bearing supports from
old vertical arm.

2.
Install horizontal arm.

a.
Lift horizontal arm into position.

Note: When installing the bearing support, the support will center the
horizontal arm. Ensure that the bearing assembly enters into the rear part
correctly.
3.
b.
Check that attachment holes in horizontal arm and bearing supports on

both sides are aligned.
c.
Install attachment screws (fig.53/6) and press bearing into position by

cross tightening screws. Perform operation on both sides.
d.
Install caps (fig.53/4) on both sides.
e.
Install cap attachment screws (fig.53/3). Tighten screws on both sides.
Attach parallel rod.

a.
Move parallel rod into position on rear end of horizontal arm.
b.
Check that rod bearing is located in center of gap.
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c.
Install 2 screws for brackets (fig.53/2) on each side of the upper parallel
rod attachment. Tighten screws.
Note: If the horizontal arm was removed temporarily for replacement of
vertical arm, return to Installation of Vertical Arm on page 113, Step 1.b.
d.
4.
Engage balancing spring for axis 3 as described in procedure Engage

Balancing Spring on page 98.
Install connections for horizontal arm.

a.
Enter cables from vertical arm into horizontal arm rear housing and secure
2 e.a. screws for cable attachment (fig.53/8).
b.
Install cable straps.
CAUTION! The straps just above hoses inside horizontal arm serve as stress relief
for the cables.

c.
Install connectors (fig.53/11) for measuring system for motor 4, 5 and 6.
CAUTION! Connectors must be installed correctly in relation to the respective axes
as shown in Figure 56.
5.
132
d.
Install connectors (fig.53/9) for motor power for motor 4, 5 and 6.
e.
Install ground connection (fig.53/12).
f.
Install purge sensor connector just before the cover is installed.
Conclude operation.
a.
Install purge sensor connector (fig.53/10) on purge sensor in horizontal

arm rear cover.
b.
Install rear cover (fig.53/1). Make sure that seal is undamaged and properly
positioned to prevent air leaks for the purging system.
c.

on page 177.
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7.5.3 Removal of Horizontal Arm Drive Unit

Location
The horizontal arm drive unit is located on the horizontal arm as shown in the figure
below.
Figure 54 Horizontal arm drive unit, robot right side view
2
4
5
2
6
7
8
9
Horizontal arm drive unit
Drive unit attachment screws
Guide pins
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7 Repair
Purge connector
Ground connection
Purge sensor
References
No references
Tools and Items
Hand tools
Procedure
The procedure describes how to remove the horizontal arm drive unit.

1.
Prepare operation.
a.
Move vertical arm to vertical position and horizontal arm to horizontal

position.
b.
c.
Open horizontal arm rear cover (fig.54/2) and disconnect purge sensor
connector (fig.54/6) from purge sensor. The purge sensor (fig.54/9) is
installed in the horizontal arm rear cover. Remove horizontal arm rear
cover.
Note: If the robot is non-ex version, purge sensor is not installed.
2.
Remove connections for horizontal arm.

Note: Before disconnecting any connectors, carefully note position to ensure
correct reinstallation.
a.
Disconnect 3 e.a. connectors (fig.54/5) for motor power for motor 4, 5 and
6.
b.
Disconnect 3 e.a. connectors (fig.54/7) for measuring system for motor 4, 5

and 6.
WARNING! Brakes must under no circumstances be released from this point on.
Releasing the brakes from now on can cause severe injury. Brakes must not be
released again until it is clearly stated in the installation procedure.
3.
Remove horizontal arm drive unit.

a.
134
Suspend horizontal arm drive unit using a lifting strap etc.

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7 Repair
WARNING! The horizontal arm drive unit is heavy. Make sure that arm is properly
supported before removing attachment screws.
b.
Unscrew screws (fig.54/3) securing horizontal arm drive unit to rear

housing.
c.
Remove horizontal arm drive unit from rear housing, mind the guide pins
(fig.54/4).
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7.5.4 Installation of Horizontal Arm Drive Unit

Location
The horizontal arm drive unit shall be installed on the horizontal arm as shown in
the figure below.
Figure 55 Horizontal arm drive unit, robot right side view
2
4
5
2
6
7
8
9
136
Drive unit attachment screws
Guide pins
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7 Repair
Purge connector
Ground connection
Purge sensor
References
Figure 56
Tools and Items
Hand tools
Procedure
The procedure describes how to install the horizontal arm drive unit.

1.
Prepare operation.
2.
Install horizontal arm drive unit.

a.
Place horizontal arm drive unit into position on front of the rear housing.
Mind the guide pins (fig.55/4).
b.
Install screws (fig.55/3) securing drive unit to rear housing. Tighten

screws.
Note: It is now safe to release axis brakes.
3.
Install connections for horizontal arm.

a.
Install connectors (fig.55/7) for measuring system for motor 4, 5 and 6.
CAUTION! Connectors must be installed correctly in relation to the respective axes
as shown in Figure 56.
4.
b.
Install connectors (fig.55/5) for motor power for motor 4, 5 and 6.
c.
Install purge sensor connector just before the cover is installed.
Conclude operation.
a.
Install purge sensor connector (fig.55/6) on purge sensor in horizontal arm

rear cover.
b.
Install rear cover (fig.55/2). Make sure that seal is undamaged and properly
positioned to prevent air leaks for the purging system.
c.

on page 177.
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7.5.5 Removal of Motors in Horizontal Arm

Location
The motors are located in the rear housing of the horizontal arm as shown in the
figure below.
Figure 56 Location of motors, robot right side view
1
3
4
5
13
8
9
14
10
15
11
4
5
12
138
Motor attachment screws
Axis motor 4
Axis motor 5
Axis motor 6
Connector bracket
Power receptacle motor axis 5
Measuring receptacle motor axis 5
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10
11
12
Rear end rotor shaft
13
Connector bracket attachment screws
14
15
References
Removal of Horizontal Arm Drive Unit on page 133

Tools and Items
Hand tools
Procedure
The procedure describes how to remove the motors in the horizontal arm.
Note: The following guidelines are for axis 6 motor removal. Axis 4 and 5 motor
removal procedures are identical unless specifically noted.


1.
Prepare operation.
a.
b.
Remove horizontal arm drive unit as described in procedure Removal of

Horizontal Arm Drive Unit on page 133.
WARNING! Brakes must under no circumstances be released from this point on.
Releasing the brakes from now on can cause severe injury. Brakes must not be
released again until it is clearly stated in the installation procedure.
2.
c.
Place horizontal arm drive unit (fig.56/2) on a clean work table etc.
d.
Remove oil from gearbox for axis 4-6. - Ref: Replace Oil for Horizontal
Arm Gearbox on page 149 for information.
Remove connections.
a.
Remove receptacle for measuring system axis 6 (fig.56/10) from connector

bracket.
For axis 4 motor removal: (fig.56/15).
For axis 5 motor removal: (fig.56/9).
b.
Remove axis 6 motor power receptacle (fig.56/11) from connector bracket.
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For axis 4 removal: (fig.56/14).

For axis 5 removal: (fig.56/8).
c.
3.
Remove motor.
a.
140
Remove 2 e.a. attachment screws (fig.56/13) and remove connector

bracket (fig.56/7).
Unscrew 4 motor attachment screws (fig.56/3) and remove motor.
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7 Repair
7.5.6 Installation of Motors in Horizontal Arm

Location
The motors shall be installed in the rear housing of the horizontal arm as shown in
the figure below.
Figure 57 Location of motors, robot right side view
1
3
4
5
13
8
9
14
10
15
11
4
5
12
Motor attachment screws
Axis motor 4
Axis motor 5
Axis motor 6
Connector bracket
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10
11
12
Rear end rotor shaft
13
Connector bracket attachment screws
14
15
References

Installation of Horizontal Arm Drive Unit on page 136
Tools and Items
Wrist axes rotor rotating tool

Hand tools
Procedure
The procedure describes how to install the motors in the horizontal arm.
Note: The following guidelines are for axis 6 motor installation. Axis 4 and 5 motor
installation procedures are identical unless specifically noted.


1.
Prepare operation.
2.
3.
Install new motor.

a.
Place motor in correct position on horizontal arm rear flange. If possible,

with regard to the cables, place motor so that identification label is facing
up. (Motor can be installed in all four 90 positions).
b.
Install 4 motor attachment screws (fig.57/3).
Align motor.
a.
Install screw of rotor rotating tool on rear end of rotor shaft (fig.57/12).
Rotate tool until it stops. Tighten lightly.
b.
Release axis brakes for motor. - Ref: Releasing Axis Brakes on page 77.
CAUTION! It is safe to release brakes for the axis motors 4, 5 and 6 on the
horizontal arm BUT NOT ON THE ROBOT ITSELF.

c.
142
Rotate rotor a number of revolutions until finding the point where the play
between motor shaft gear wheel and gear wheel for wrist drive shaft is at a
minimum. (A full rotation of the wrist drive shaft requires
approx. 17 revolutions of the motor rotor).
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7 Repair
4.
d.
Loosen motor attachment screws (fig.57/3) a little until the motor can be
moved. Slightly adjust the motor until no play can be felt. Tighten screws
lightly.
e.
Rotate rotor to feel that it can be freely rotated over the full rotation of the
wrist drive shaft.
f.
Tighten motor attachment screws (fig.57/3).
a.
Reinstall connector bracket (fig.57/7).
b.
Install measuring system receptacle (fig.57/10) on bracket.

For axis 4 motor installation: (fig.57/15).
c.
Install power receptacle (fig.57/11) on bracket.

5.
Conclude operation.
a.
Refill oil in gearbox. - Ref: Replace Oil for Horizontal Arm Gearbox on
b.
Install horizontal arm drive unit as described in procedure Installation of

CAUTION! It is now safe to release axis brakes.
c.

on page 177.
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7.5.7 Removal of Wrist Transmission Shafts

Location
The wrist transmission shafts are located in the horizontal arm as shown in the
figure below.
Figure 58 Location of wrist transmission shafts
2
Transmission shafts
8
3
9
5
10
144
Hollow wrist
Motor unit
Transmission shaft axis 4
3HNA010055-001 en Rev.12
7 Repair
Radial seals
Guide pins
Motor unit attachment screws
10
Ball bearing attachment screws
References
Removal of Horizontal Arm Drive Unit on page 133

Removal of Wrist Unit on page 152
Tools and Items
Hand tools
Procedure
The procedure describes how to remove the wrist transmission shafts.


1.
Prepare operation.
a.
2.
3.
b.
Remove horizontal arm drive unit as described in procedure Removal of

c.
Remove wrist. Refer to Removal of Wrist Unit on page 152.
d.
Remove oil from gearbox for axis 4-6. - Ref: Replace Oil for Horizontal
Arm Gearbox on page 149 for information.
Remove motor unit.

a.
Remove screws (fig.58/9) securing motor unit (fig.58/3) to horizontal arm.
b.
Remove motor unit from horizontal arm.
Remove drive shafts.

a.
Remove 3 pair of screws (fig.58/10) securing ball bearings for axis 4

(fig.58/4), axis 5 (fig.58/5) and axis 6 (fig.58/6) drive shafts. Screws are
reached through holes in drive shaft gear wheels. Rotate gear wheels as
required to align with screws.
b.
Pull out all 3 drive shafts. Knock carefully with a plastic hammer at front
to free shaft bearings.
c.
Remove drive shafts. Note that drive shaft 4 is longer than drive shaft 5
and 6. In addition, the drive shaft for axis 6 (center drive shaft) has a longer
distance between the gear wheel and the bearing.
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7.5.8 Installation of Wrist Transmission Shafts

Location
The wrist transmission shafts shall be installed in the horizontal arm as shown in the
figure below.
Figure 59 Location of wrist transmission shafts
2
Transmission shafts
8
3
9
5
10
146
Hollow wrist
Motor unit
3HNA010055-001 en Rev.12
7 Repair
Radial seals
Guide pins
Motor unit attachment screws
10
Ball bearing attachment screws
References

Installation of Horizontal Arm Drive Unit on page 136
Installation of Motors in Horizontal Arm on page 141
Installation of Wrist Unit on page 154
Tools and Items
Hand tools
Loctite 270 glue (green)
Procedure
The procedure describes how to install the wrist transmission shafts.


1.
Prepare operation.
2.
Install new drive shafts.

a.
Add a little Kernite K-NATE NLGI-2 grease to each of the 3 radial seals
(fig.59/7).
b.
Add a little Loctite 270 glue (green) to each of the bearings.
c.
Enter the drive shafts into their respective radial seal. Be careful not to
damage the seals.
CAUTION! A damaged radial seal must be replaced. If not inner oil leaks will occur.
d.
Bring the 3 shaft gear wheels together and push all 3 drive shafts through
horizontal arm.
Note: The 3 shafts are different and can be identified as follows: Axis 4
shaft (fig.59/4) is the longest, axis 6 shaft (fig.59/6) has a longer distance
between the gear wheel and the ball bearing.
e.
While guiding the drive shafts at the front of the horizontal arm, push the
drive shafts fully into position. Carefully knock on the shafts using a
plastic hammer if required.
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7 Repair
f.
3.
Install screws (fig.59/10) securing ball bearings. Rotate gear wheels as

required for access.
Install motor unit.

a.
Ensure that guide pins (fig.59/8) on horizontal arm flange are in position.
b.
Install motor unit.

Note: You may have to wiggle motor unit and drive shafts to align teeth of
gear wheels as an alternative to releasing the brakes for the motors. - Ref:
4.
148
c.
Install screws (fig.59/9) securing motor unit to horizontal arm. Tighten

screws.
d.
Check that gearbox is properly sealed before filling oil. This can be
checked by connecting pressurized air and gauge to the filling hole. Apply
0.5 bar and check that no leaks can be observed. If leaks are present, try to
locate leaks using water and soap. Correct leak by replacing o-ring
between drive unit and horizontal arm flange or replace radial seal as
necessary.
e.
Refill oil in gearbox. - Ref: Replace Oil for Horizontal Arm Gearbox on
Conclude operation.
a.
Install horizontal arm drive unit as described in procedure Installation of

b.
Install wrist. Refer to Installation of Wrist Unit on page 154.
c.
Check alignment of drive motors. Refer to Installation of Motors in

Horizontal Arm on page 141, Step 3.
d.

on page 177.
3HNA010055-001 en Rev.12
7 Repair
7.5.9 Replace Oil for Horizontal Arm Gearbox

Location
The drain- and filling plugs are location on the horizontal arm as shown in the figure
below.
Figure 60 Location of oil plugs horizontal arm gearbox (axes 4-6)
Filling plug - horizontal arm gearbox
Level
Horizontal arm
Drain plug - horizontal arm gearbox
References

Tools and Items
Hand tools
Oil Specification
Oil type:
Quantity:
Approx. 1.0 liter
Level:
65-75 mm below filling hole
Note: Oil quantity refers to an empty, clean gearbox. Later refilling will require a
lower quantity.
Procedure
The procedure describes how to replace oil for horizontal arm gearbox.

WARNING! Before starting to replace oil, observe Safety Instructions for
Replacing Oil in Gearboxes on page 192.

1.
Remove oil.
a.
Release axis brakes, see Releasing Axis Brakes on page 77, and place the
horizontal arm in horizontal position. Activate brakes.
b.
Place a tray or similar under oil drain plugs underneath horizontal arm.
c.
Remove one drain plug and drain oil.
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7 Repair
d.
2.
Clean drain plug. Re-install plug and tighten.
Fill new oil.

a.
Remove filling plug on top of gearbox.
b.
Fill gearbox with Mobil MobilgearTM 600 XP 320 until oil level is as
specified, see Oil Specification on page 149.
c.
Clean filling plug. Reinstall plug and tighten.
Note: Oil drained from the manipulator must be disposed of in accordance with
local regulations.
150
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7 Repair
7.6 Hollow Wrist Unit Guidelines

General

hollow wrist unit.
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7.6.1 Removal of Wrist Unit

Location
The wrist is located at the front of the horizontal arm. The wrist is shown in the
figure below.
Figure 61 The hollow wrist unit
1
Hollow wrist
Hollow wrist attachment screws
Rear seal
References
No references
Tools and Items
Hand tools
Procedure
The procedure describes how to remove the hollow wrist unit.


1.
Prepare operation.
a.
2.
152
Remove wrist.
a.
Carefully, not to damage the seal seat, insert a screwdriver between rear
seal and seal seat on hollow wrist.
b.
Remove seal out of seat and move the seal a little to the front.
3HNA010055-001 en Rev.12
7 Repair
c.
Remove 10 screws securing wrist flange to front of horizontal arm. The

location of the screw attachment holes on the front of the horizontal arm is
shown in the illustrations below (fig.62/4).
Figure 62 Wrist unit rear end and horizontal arm front
1
2
3
4
5
d.
Grip wrist with both hands (Weight approximately 13 kg). Hold wrist
firmly and wiggle from side to side to remove.
e.
If ball bearing (fig.62/1) needs replacement, remove bearing using a puller.
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7 Repair
7.6.2 Installation of Wrist Unit

Location
The wrist shall be installed at the front of the horizontal arm. The wrist is shown in
the figure below.
Figure 63 The hollow wrist unit
1
Hollow wrist
Hollow wrist attachment screws
Rear seal
References
Figure 62
Tools and Items
Procedure
The procedure describes how to install the hollow wrist unit.
Hand tools
Shell Alvania EP2 LF grease

1.
Prepare operation.
2.
Install wrist.
a.
154
If bearing (fig.62/1) was removed, add Shell Alvania EP2 LF grease to

inside of bearing. Add a little Loctite 270 glue (green) on inner ring,
3HNA010055-001 en Rev.12
7 Repair
place bearing in position and carefully knock into position using a plastic
hammer. Make sure that bearing is properly positioned.
b.
Lubricate front of ball bearing (fig.62/2) using Shell Alvania EP2 LF

grease.
c.
Lubricate gear wheels on wrist (fig.62/6) and horizontal arm (fig.62/5)

using Kernite K-NATE NLGI-2 grease.
d.
Lubricate o-ring (fig.62/7) and inside of hole (fig.62/3) in horizontal arm

front using Kernite K-NATE NLGI-2 grease.
e.
Hold wrist with both hands and place it into position on horizontal arm
front. Wiggle wrist carefully to get all gears into grip. Push wrist fully into
position.
f.
Install 10 attachment screws and tighten.
g.
Install rear seal in seal seat. Add a little Kernite K-NATE NLGI-2 grease to
seal seat as required.
CAUTION! Be careful not to damage the seal during installation.
3.
Conclude operation.
a.

on page 177.
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7 Repair
7.6.3 Removal of Wrist Inner Flexible Hose

Location
The wrist inner flexible hose is located in the wrist unit as shown in the figure
below.
Figure 64 Wrist unit, right side view
1
3
1
Horizontal arm
Wrist unit
Hose guide tube
Inner flexible hose
Supply hoses
References
Removal of Wrist Unit on page 152
Tools and Items
Hand tools
Procedure
The procedure describes how to remove the wrist inner flexible hose.

1.
Prepare operation.
a.
b.
Remove spray-gun, gun attachment and supply hoses as required.

Note: If wrist can be removed and re-installed without changing the
position of any of the 3 joints, calibration will not be required. Mark
156
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7 Repair
position of wrist and all joints as required to make sure that they will not be
moved.
2.
c.
Remove wrist from horizontal arm as described in Removal of Wrist Unit

on page 152.
d.
Place wrist on a clean workbench with the front facing up.
Remove flexible hose.
Figure 65 Wrist unit, front end
3
2
a.
Loosen 4 screws (fig.65/3) securing front ring (fig.65/1) of flexible hose

(fig.65/2) to front of wrist. Do not remove screws.
b.
Grab front ring (fig.65/1) with fingers to feel that the ring is free.
c.
Turn wrist unit upside down so that it is now standing on its front end.
d.
Loosen 2 screws (fig.66/2) securing rear ring of flexible hose (fig.66/1) to

rear of wrist.
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7 Repair
Figure 66 Wrist unit, rear end
158
e.
Pull flexible hose out from rear end of wrist.
f.
Discard old flexible hose.
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7 Repair
7.6.4 Installation of Wrist Inner Flexible Hose

Location
The wrist inner flexible hose shall be installed in the wrist unit as shown in the
figure below.
1
3
1
Horizontal arm
Wrist unit
Hose guide tube
Inner flexible hose
Supply hoses
Connection
References
Installation of Wrist Unit on page 154

Figure 65
Figure 66
Tools and Items
Hand tools
Procedure
The procedure describes how to install the wrist inner flexible hose.

1.
Prepare operation.
2.
Install new flexible hose.
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7 Repair
3.
160
a.
Lubricate flexible hose using Kernite K-NATE NLGI-2 grease.
b.
Slide new hose into wrist from the rear end. Press hose as far down as
practical.
c.
Turn wrist upside down so that front is facing up.
d.
Pull flexible hose up with fingers until front of ring is aligned with inner
flange of wrist front ring.
e.
Tighten flexible hose with screws (fig.65/3).
f.
Turn wrist so that rear end is facing up.
g.
Tighten flexible hose with screws (fig.66/2) at rear end.
Conclude operation.
a.
Install wrist on horizontal arm as described in Installation of Wrist Unit

on page 154.
b.
If required, calibrate the robot. For information, see Calibration Fixture

Installation on page 177.
c.
Install spray-gun, gun attachment and supply hoses as required.
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7 Repair
7.6.5 Replace Wrist Seals

Location
The wrist seals are located on the wrist unit as shown in the figure below.
Hollow wrist
Rear seal
Axis 6 rear seal
Axis 6 front seal
Front seal
References
No references
Tools and Items
Hand tools
Procedure
The procedure describes how to replace the wrist seals.


1.
Prepare operation.
a.
2.
Remove old seals.
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7 Repair
3.
a.
Carefully, not to damage the seal seat, insert a screwdriver between seal
and seal seat.
b.
Remove seal.
c.
Repeat operation for all seals to be removed.
Install new seals.

a.
Add a little Kernite K-NATE NLGI-2 grease to seal seat.
CAUTION! Be careful not to damage the seals during handling and installation.
b.
Install new seal, making sure that seal is installed in correct direction, see
Figure 68.
Note: The front seal is specially formed at the calibration mark, and shall
only be installed in one correct way.

c.
162
Repeat operation for all seals.
3HNA010055-001 en Rev.12
7 Repair

General
The following procedures provide information for replacing cable units for the
IRB 580 robots.
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7.7.1 Removal of Cables Horizontal - Vertical Arm

Location
The cables between the horizontal- and vertical arm are located on the robot as
shown in the figure below.
Figure 69 Cables horizontal arm - vertical arm
1
3
2
4
7
Vertical arm front cover
3-7
Connectors in vertical arm
References
No references
Tools and Items
Hand tools
Procedure
The procedure describes how to remove the cables between the horizontal arm and
the vertical arm.

1.
164
Prepare operation.
a.
Place robot in a convenient position, e.g. vertical arm 30 backward and

horizontal arm in horizontal position.
b.
Turn electrical disconnect switch off and lock switch in off position.
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7 Repair
2.
c.
d.
Remove horizontal arm rear cover (fig.69/1).
Remove connections for left cable/hose harness.

carefully note position to ensure correct installation of new cable.
3.
a.
Disconnect relevant connectors, cable clamp, ground wires and cable strap
in horizontal arm.
b.
Disconnect relevant connectors (fig.69/5, 6), ground wire (fig.69/7), cable

clamp and cable straps in vertical arm.
Remove connections for right cable/hose harness.

4.
a.
Disconnect relevant connectors and cable strap in horizontal arm.
b.
Disconnect relevant connectors (fig.69/3, 4) in vertical arm.
Remove both cable/hose harnesses.

a.
Remove screws securing cable hoses to vertical- and horizontal arm.
b.
Pull out complete cable/hose harnesses.
c.
Discard old cable/hose harnesses.
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7.7.2 Installation of Cables Horizontal - Vertical Arm

Location
The cables between the horizontal- and vertical arm shall be installed on the robot as
Figure 70 Cables horizontal arm - vertical arm
1
3
2
4
7
3-7
References
No references
Tools and Items
Hand tools
Procedure
The procedure describes how to install the cables between the horizontal arm and
the vertical arm.

1.
Prepare operation.
a.
2.
166
Install both cable/hose harnesses.
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7 Repair
3.
a.
Route new cables into hose entrances in vertical- and horizontal arm.
b.
Move hoses fully into position.
c.
Install hose attachment screws and secure hoses to vertical- and horizontal
arm.
d.
Route cables down inside vertical arm.
Install connections for left cable/hose harness.


a.
Install connectors, cable clamp, ground wire(s) and cable strap in

horizontal arm.
Note: Remember strap just above hose in horizontal arm. This strap is
important as it serves as stress relief for the cables.

b.
4.
Install connectors (fig.70/5, 6), ground wire (fig.70/7), cable clamp and
cable straps in vertical arm.
Install connections for right cable/hose harness.


a.
Install connectors and cable strap in horizontal arm.

Note: Remember strap just above hose in horizontal arm. This strap is
important as it serves as stress relief for the cables.
b.
5.
Install connectors (fig.70/3, 4) in vertical arm.
Conclude operation.
a.
Install covers on vertical- and horizontal arm.
b.

on page 177.
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7.7.3 Removal of Cables Vertical Arm - Base Unit

Location
The cables between the vertical arm and base unit are located on the robot as shown
in the figure below.
Figure 71 Cables vertical arm - base unit
1
7
4
5
3
2
9
Base unit front cover
Base unit rear cover
4-9
References
No references
Tools and Items
Hand tools
Procedure
The procedure describes how to remove the cables between the vertical arm and the
base unit.

1.
168
Prepare operation.
a.
Place robot in a convenient position, e.g. vertical arm in vertical position.
b.
3HNA010055-001 en Rev.12
7 Repair
2.
c.
d.
Remove base front (fig.71/2) and rear (fig.71/3) covers.
Remove connections for left cable/hose harness.

3.
a.
Disconnect relevant connector (fig.71/9), socket (fig.71/7), ground wire

(fig.71/8), cable clamps and cable straps in vertical arm. The socket is
installed on a bracket. To remove it, first disconnect corresponding
connector.
b.
Disconnect relevant connectors, cable clamps and ground wire in base unit
rear side.
Remove connections for right cable/hose harness.

4.
a.
Disconnect relevant connector (fig.71/6), sockets (fig.71/4, 5) and cable

clamps in vertical arm. The sockets are installed on a bracket. To remove
them, first disconnect corresponding connector.
b.
Disconnect relevant connectors, cable clamps and cable coupling

connector in base unit front side.
Remove both cable/hose harnesses.

a.
Remove screws securing cable hoses to vertical arm and base unit.
b.
Pull out complete cable/hose harnesses.
c.
Discard old cable/hose harnesses.
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7 Repair
7.7.4 Installation of Cables Vertical Arm - Base Unit

Location
The cables between the vertical arm and base unit shall be installed on the robot as
Figure 72 Cables vertical arm - base unit
1
7
4
5
3
2
9
4-9
References
No references
Tools and Items
Hand tools
Procedure
The procedure describes how to install the cables between the vertical arm and the
base unit.

1.
Prepare operation.
a.
170
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7 Repair
2.
3.
Install both cable/hose harnesses.

a.
Route new cables into hose entrances in vertical arm and base unit.
b.
Move hoses fully into position.
c.
Install attachment screws and secure hoses to vertical arm and base unit.
d.
Route cables inside vertical arm.
e.
Route cables inside base unit.
Install connections for left cable/hose harness.

4.
a.
Install connector (fig.72/9), socket (fig.72/7), cable clamps, ground wire

(fig.72/8) and cable straps in vertical arm. Remember to connect the
corresponding connector to the newly installed socket.
b.
Install ground wire, connectors and cable clamps in base unit rear side.
Install connections for right cable/hose harness.

5.
a.
Install connector (fig.72/6), sockets (fig.72/4, 5) and cable clamps in

vertical arm. Remember to connect the corresponding connectors to the
newly installed sockets.
b.
Install connectors, cable clamps and cable coupling connector in base unit
front side.
Conclude operation.
a.
Install covers on vertical arm and base unit.
b.

on page 177.
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7 Repair
7.7.5 Removal of Cables Base Unit - Foot Unit

Location
The cables between the base unit and foot unit are located on the robot as shown in
the figure below.
Figure 73 Cables base unit - foot unit
2
3
Foot unit top cover
References
No references
Tools and Items
Hand tools
Procedure
The procedure describes how to remove the cables between the base unit and the
foot unit.

1.
172
Prepare operation.
a.
Place robot in a convenient position to get access to the base unit front and
rear sides and the foot unit junction box, e.g. positioned like in Figure 73.
b.
3HNA010055-001 en Rev.12
7 Repair
2.
c.
Remove foot unit top cover (fig.73/3).
d.
Remove base front (fig.73/1) and rear (fig.73/2) covers.
Remove connections.
3.
a.
If applicable, disconnect and remove back-up battery in foot unit. Retain

battery for re-installation.
b.
Disconnect all external cabling connected to the termination bracket in foot

unit.
c.
Disconnect relevant sockets, cable clamps and ground wire in base unit
rear side. The sockets are installed on a bracket. To remove them, first
disconnect the corresponding connector.
d.
Disconnect relevant connectors, socket, cable coupling connector and

cable clamps in base unit front side. The socket is installed on a bracket. To
remove it, first disconnect the corresponding connector.
Remove cable/hose harness.

a.
Remove screws on top of base unit securing cable hose, between base unit
and foot unit, to base unit.
b.
Loosen hose nut in foot unit by hand and lift hose out of the termination
bracket. The 2 nuts securing the termination bracket are now visible,
remove these 2 nuts.
c.
Pull out complete cable/hose harness, start with termination bracket in foot
unit.
d.
Discard old cable/hose harness, including termination bracket.
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7 Repair
7.7.6 Installation of Cables Base Unit - Foot Unit

Location
The cables between the base unit and foot unit shall be installed on the robot as
Figure 74 Cables base unit - foot unit
2
3
Foot unit top cover
References
No references
Tools and Items
Hand tools
Procedure
The procedure describes how to install the cables between the base unit and the foot
unit.

1.
Prepare operation.
a.
2.
174
Install cable/hose harness.
3HNA010055-001 en Rev.12
7 Repair
3.
a.
Route new cables via foot unit into hose entrance in base unit.
b.
Move hose fully into position in base unit.
c.
Install hose screws on top of base unit and secure hose to base unit.
d.
Install attachment nuts and secure termination bracket in foot unit.
e.
Move hose fully into position in termination bracket, tighten hose nut by
hand and secure hose to termination bracket.
f.
Route cables inside base unit.
4.
a.
Install sockets, cable clamps and ground wire in base unit rear side.
Remember to install the corresponding connectors to the newly installed
sockets.
b.
Install connectors, socket, cable coupling connector and cable clamp in

base unit front side. Remember to connect the corresponding connector to
the newly installed socket.
c.
Install external cabling to the termination bracket in foot unit.
d.
If applicable, install back-up battery in foot unit and connect battery

connector.
Conclude operation.
a.
Install covers on base unit and foot unit.
b.

on page 177.
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7 Repair
176
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7 Repair
7.8 Calibration Fixture Installation

7.8.1 Introduction
General
The following provides instructions for installation of the calibration fixture for the
robot main axes and the hollow wrist.
The illustrations for calibration fixture installation also include information on
location of calibration marks and calibration position values.
A calibration fixture is required to perform the calibrating operation.
Note: The following only includes information for installation of the calibration
fixture. For description of the calibration function and procedure for entering
calibration data, see Operators Manual, IRC5P.
Safety Information
Before any calibration work is commenced, it is extremely important that all safety
information is observed.
guidelines in the Safety Manual have been read and understood. Work must only be
performed by skilled personnel with the proper training.
Safety Information for

Calibration
Changing calibration data are operations which may result in unexpected motion of
the robot or cause the robot to race if performed incorrectly. Following points
MUST therefore be observed when running or starting the robot after having
changed the calibration data.
ALWAYS check that the calibration fixture has been removed and that no person
or object is within the reach of the robot arm before applying power to the robot
and/or starting the robot.
ALWAYS stand ready by an EMERGENCY STOP before applying power to the
robot and/or starting the robot.
ALWAYS check movement of all robot axes in both directions after calibration
has been performed.
Installing the calibration fixtures involves releasing the axis brakes. Even if the
manipulator is counter balanced, attention must be paid to possible dropping or
raising of the arm, depending on horizontal arm type and weight installed on the
arm.
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7 Repair
7.8.2 Calibration Fixture Installation, Axes 1,2,3

General
Following procedure describes how to install the calibration fixture for the main
axes. The illustration also shows the location of the calibration marks.
Figure 75 Calibration fixture installation, main axes
Calibration
marks, Axis 3
10
9
6
8
Calibration marks,
Axis 2
Axis 3 fixture
Axis 2 fixture
Located on
inner surface
1
3
2
Calibration
marks, Axis 1
2
Axis 1 fixture
Robot type
IRB 580-12 - 1620 mm horizontal arm
IRB 580-12 - 1220 mm horizontal arm
Axis 1
0
0
Calibration Position Values

Axis 2
Axis 3
45.66
0
37.72
0
Axis 7 *1
0
0
*1 Axis 7 applies for trolley version
For information on robot type, see Manipulator Versions on page 36.

Procedure
178
Following procedure describes how to install the calibration fixture for axis 1, 2 and
3 on the manipulator.
3HNA010055-001 en Rev.12
7 Repair
regulations in Safety Information on page 177 and Safety Information for

Calibration on page 177 have been read and understood.
1.
Release the axis brakes, see Releasing Axis Brakes on page 77. Then install
calibration fixture for the required main axes as follows.
2.
Rotate axis 1 to a position where the two studs (fig.75/1) on the foot unit and
the stud (fig.75/2) on the base unit are lined up as shown in Figure 75.
3.
Install the calibration fixture (fig.75/3) across the studs and tighten screw
(fig.75/4).
4.
Remove protective screw from alignment hole (fig.75/5) on vertical arm.
5.
Move axis 2 (vertical arm) to the position shown in Figure 75 and install the
calibration fixture (fig.75/6) on vertical arm alignment stud (fig.75/5) and lay
calibration fixture upon base alignment stud (fig.75/7). Move vertical arm
manually backwards such that alignment stud (fig.75/7) fits in the calibration
fixture.
6.
Remove protective screw from alignment hole (fig.75/8) on vertical arm and
alignment hole (fig.75/10) on horizontal arm.
7.
Move axis 3 (horizontal arm) to the position shown in Figure 75 and install the
calibration fixture (fig.75/9) between alignment holes on the vertical and
horizontal arm.
8.
Activate brakes.
CAUTION! After the calibration is completed, remove calibration fixture and reinstall protective screws.
Note: If the robot is operating on a trolley, axis 1 calibration can be
checked/optimized for small inaccuracies related to the rail. For information on this
and information on calibrating the trolley motion, see Product Manual, Rail
System.
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7 Repair
7.8.3 Calibration Fixture Installation, Hollow Wrist

General
Following procedure describes how to install the calibration fixture for the hollow
wrist axes. The illustration also shows the location of the calibration marks.
Figure 76 Calibration fixture installation, hollow wrist
5
Axis 4
Axis 6
Calibration
mark axis 4
Calibration
mark axis 5
Procedure
Axis 5
Calibration
mark axis 6
Calibration Position Values

Axis 4
Axis 5
0
0
Axis 6
0
Following procedure describes how to install the calibration fixture for the hollow
wrist.
regulations in Safety Information on page 177 and Safety Information for

Calibration on page 177 have been read and understood.
1.
Release the axis brakes, see Releasing Axis Brakes on page 77, and rotate
axis 4, 5 and 6 to the position shown in Figure 76.
2.
Align axis 6 notch (fig.76/1) and axis 5 stud (fig.76/2) horizontally and axis 4
guide pin (fig.76/3) upwards.
Note: When aligning axis 6, check that the axis is in the correct revolution as
hoses are concerned. This can be found by looking or feeling that the hoses at
the outlet in the rear end of the arm are not twisted or strained.
3.
180
Install rear fixture section (fig.76/4). Align fixture guide pins (fig.76/8) on axis
5 studs (fig.76/2) and top slot on axis 4 guide pin (fig.76/3). Install screws
(fig.76/5) on both sides of arm to lock axis 4 in a fixed position.
3HNA010055-001 en Rev.12
7 Repair
4.
Install front fixture section (fig.76/6) while checking that alignment notches
(fig.76/1) are properly engaged. Tighten screw (fig.76/7) to lock axis 5 and 6 in
a fixed position.
5.
Activate brakes.
CAUTION! After the calibration is completed, remove calibration fixture.
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7 Repair
182
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8 Decommissioning
8 Decommissioning
General
The components of the robot are manufactured from many different materials. Some
of them are listed below to facilitate scrapping, i.e. so that the components can be
disposed of in a way that does not have a detrimental effect on anyones health or
the environment.
CAUTION! Decommissioning must always be performed in accordance with
standards and regulations of the country where the robot is installed.
Manipulators
Material
Examples of components
Part of
Copper
Cables, motors
All robot types
Cast iron/nodular iron
Foot unit
IRB 5500
Foot unit, base unit,

IRB 5400 / IRB 580
vertical arm (axis 2 arm) lower part
Steel
Foot unit, base, arm assembly
IRB 52
Servo unit E11
IRB 5320
Foot unit, inner arm
IRB 5350
Gears, screws, base-frame, etc.
All robot types
Arm
IRB 5320
Front sheet
IRB 5310 CBS II
Samarium-Cobalt
Brakes, motors
All robot types
Plastic/rubber (PVC)
Cables, connectors, drive belts etc. All robot types
Oil, grease
Gearboxes
All robot types
Aluminium
Covers, sync. brackets
All robot types
Vertical/horizontal arm
(axis 2 arm/axis 3 arm)
All robot types except IRB 52
Base unit
IRB 5500
Servo unit E21
IRB 5320
Outer arm and tower
IRB 5350
Castings in wrist, arms
All robot types
Frame
IRB 5310 CBS II
Control Cabinet
Material
Examples of components
Copper
Transformers, cables
Tin
Cables
Alu-Zinc sheets
Control cabinets, various sheet material parts
Iron
Transformers
Polyester
Circuit boards
Plastic/rubber (PVC)
Cables, connectors, pendant, covers (drive units, I/O units) etc.
Lithium
Batteries
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183
8 Decommissioning
Scrapping
Following warning must be observed before disassembling.

WARNING! Before removing any parts from the manipulator, study the removal
instructions for the component in question.
Oil and Grease
Where possible, arrange for the 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 may form a film on water surfaces causing damage to organisms. Oxygen
transfer could also be impaired.
Spillage may penetrate the soil causing ground water contamination.
Balancing system
If the robot includes balancing springs, special care is needed when removing the
balancing system.
The balancing system contains 2 preloaded spiral springs. Before scrapping
(melting down, or other form of destruction) the springs must be unloaded in a safe
way.
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3HNA010055-001 en Rev.12
9.1 Introduction
9.1 Introduction
About this Chapter
This chapter includes various information complementing the more specific

information in the previous chapters.
Following sections are included:
Mounting Instructions for Bearings on page 186

Mounting Instructions for Seals on page 187
Tightening Torques on page 189
Loctite Specifications on page 191
Oil Type Specifications on page 193
Grease Type Specifications on page 195
3HNA010055-001 en Rev.12
185
9.2 Mounting Instructions for Bearings
9.2 Mounting Instructions for Bearings

General
This section details how to mount and grease different types of bearings on the
manipulator.
Mounting
Following points must be observed when mounting a bearing on the manipulator.

To avoid contamination, let a new bearing remain in its wrapping until it is time
for fitting.
Ensure that all parts included in the bearing fitting are free from burrs, grinding
waste and other contamination. Cast components must be free from foundry
sand.
Bearing rings, inner rings and roller elements must under no circumstances be
subjected to direct impact. Furthermore, the roller elements must not be exposed
to any stresses during the assembly work.
Following additional points must be observed for tapered bearings to enable the
roller elements to adjust to the correct position against the race flange.
The bearing must be tensioned gradually until the recommended pre-tension is
achieved.
The roller elements must be rotated a specified number of turns before pretensioning is carried out, and also rotated during the pre-tensioning sequence.
Make sure that the bearing is properly aligned, as this will directly affect the
lifespan of the bearing.
Greasing
Following points must be observed when greasing a bearing.

The bearings must not be completely filled with grease. However, if space is
available beside the bearing fitting, the bearing may be totally filled with grease
when mounted, as excessive grease will be pressed out from the bearing when
the robot is 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.
186
3HNA010055-001 en Rev.12
9.3 Mounting Instructions for Seals

General
A common cause of leakage in seals is incorrect fitting. This section details how to
mount different types of seals on the manipulator.
General Precautions
Following points must be observed before commencing any assembling of seals.

Protect the sealing surfaces during transport and mounting.
Keep the seal in the original wrappings or protect it well before actual mounting.
If the fitting of seals and gears is not performed directly on the robot, the fitting
must be carried out on a clean workbench.
Use a protective sleeve for the seal during mounting, when sliding over threads,
keyways, etc.
Rotating Seals
Flange Seals and Static

Seals
The instruction below details how to fit rotating seals.

1.
Check the seal to ensure that the seal is of the correct type (provided with
cutting edge), and that there is no damage to the sealing edge (feel with a
fingernail).
2.
Inspect the sealing surfaces before mounting. If scratches or damage are found,
the seal must be replaced, as it may result in future leakage.
3.
Lubricate the seal with grease just before fitting. (Not too early as there is a risk
of dirt and foreign particles adhering to the seal.) Fill the space between the
dust tongue and sealing lip to 2/3 with grease. The rubber coated external
diameter must also be greased, unless otherwise specified.
4.
Mount the seal correctly using a mounting tool. Never hammer directly on the
seal, as this may result in leakage.
The instruction below details how to fit flange seals and static seals.
1.
Check the flange surfaces. They must be even and free from pores. It is easy to
check flatness using a gauge on the fastened joint (without sealing compound).
If the flange surfaces are defective, the parts may not be used, because leakage
could occur.
2.
Clean the surfaces properly.
3.
Distribute the sealing compound evenly over the surface, preferably with a
brush.
4.
Tighten the screws evenly when fastening the flange joint.
3HNA010055-001 en Rev.12
187
O-rings
188
The instruction below details how to fit o-rings.

1.
Ensure that the correct o-ring size is used.
2.
Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective
o-rings must not be used.
3.
Check the o-ring grooves. The grooves must be geometrically correct and free
from pores and contamination. Defective o-rings must not be used.
4.
Lubricate the o-ring with Grease, free of products that may react with paint, ie.
grease free of silicone, perfluorinated polyether, etc.
5.
Tighten the screws evenly when assembling.
3HNA010055-001 en Rev.12
9.4 Tightening Torques

Description
It is of the utmost importance that all screws are tightened with the correct torque.
All screws in metallic materials on the robot, except for adjusting screws, must be
tightened with torque according to the tables below unless otherwise specified.
These instructions do not apply to screw joints comprising soft or brittle materials.
Galvanized screws are of 8.8 quality and untreated screws (black oxide) are of 12.9
quality. Torques apply to lightly lubricated screws.
Hexagon Socket Head
The table below shows tightening torques to be used for screws with hexagon socket
head.
Nominal
diameter
Slotted or Cross
Recessed Head
Screw quality
12.9
M4
2.9 Nm
4.9 Nm
M5
5.9 Nm
10.0 Nm
M6
9.9 Nm
16.5 Nm
M8
24.0 Nm
40.0 Nm
M10
47.0 Nm
79.0 Nm
M12
82.0 Nm
140.0 Nm
M14
130.0 Nm
220.0 Nm
M16
200.0 Nm
340.0 Nm
The table below shows tightening torques to be used for screws with slotted or cross
recessed heads, as used for electrical connections, terminal board screws etc.
Nominal
diameter
Tightening torque
Screw quality
8.8
Tightening torque
Screw quality
4.8 Dry
M2.5
0.25 Nm
M3
0.5 Nm
M4
1.2 Nm
M5
2.5 Nm
M6
5.0 Nm
3HNA010055-001 en Rev.12
189
Stainless Steel Screws
The table below shows tightening torques to be used for stainless steel screws. The
screws need to be greased. If Loctite is not described, use Grease, free of products
that may react with paint, ie. grease free of silicone, perfluorinated polyether, etc.
Nominal
diameter
190
Tightening torque
Screw quality A2 / A4
50
70
80
M5
1.9 Nm
4.1 Nm
5.4 Nm
M6
3.3 Nm
7.0 Nm
9.3 Nm
M8
7.8 Nm
17.0 Nm
22.0 Nm
M10
15.0 Nm
33.0 Nm
44.0 Nm
M12
27.0 Nm
57.0 Nm
76.0 Nm
M16
65.0 Nm
140.0 Nm
187.0 Nm
M20
127.0 Nm
273.0 Nm
364.0 Nm
M24
230.0 Nm
472.0 Nm
629.0 Nm
3HNA010055-001 en Rev.12
9.5 Loctite Specifications
9.5 Loctite Specifications

Description
The following Loctite types are used.

Which type to use is specified in the procedures where Loctite is required.
Note: Do not use Loctite Glue on Hexagon socket head cap screws (guide screws)
with grounded cylindrical stem BS 4168 - ISO 7379, and all swivels.

Add a drop of Loctite 243 to screws which you can see have Loctite when
dismounted.
Must be used on screws where it is especially important that the screws are
firmly fixed. Screws with green Loctite are much harder to open than screws
with blue Loctite. It may be required to heat screws to be able to loosen!
Loctite 574 liquid gasket
Must be used whenever liquid gasket is specified in the procedures. Use first
Loctite 7063, or equivalent, to clean the relevant surfaces.
Loctite 577 liquid gasket
Must be used whenever liquid gasket for hoses and screws is specified in the
procedures.
Loctite 7063 solvent cleaner (or equivalent)
Must be used before liquid gasket (Loctite 574) is applied.
Teroson Terostat MS 939 sealing glue
Must be used whenever sealing glue is specified in the procedures.
3HNA010055-001 en Rev.12
191
9.6 Safety Instructions for Replacing Oil in Gearboxes
9.6 Safety Instructions for Replacing Oil in Gearboxes

Description
When handling the gearbox oil, there are several dangers to both personal injuries
and product damages. Following safety information must be regarded before
performing any work with the oil in the gearboxes.
Changing and draining gearbox oil may require handling hot oil of up to 90 C.
Make sure that protective gear like goggles and gloves are worn during this
activity.
When opening the oil plug, there may be pressure present in the gearbox,
causing oil to spray from the opening. Open oil plug carefully and keep away
from the opening.
Overfilling of gearbox oil can lead to internal high pressure inside the gearbox
which in turn may damage seals and gaskets, completely press out seals and
gaskets and/or prevent the manipulator from moving freely. Make sure not to
overfill the gearbox. After filling, check that the oil level is correct.
Mixing types of oil may cause severe damage to the gearbox. When filling
gearbox oil, do not mix different types of oil. Always use the specified oil type.
Warm oil drains quicker than cold oil. When changing gearbox oil, first run the
robot for a time to heat up the oil.
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox. After
refilling, check the oil level.
192
3HNA010055-001 en Rev.12
9.7 Oil Type Specifications

9.7.1 Description
Oil Types
Following oil types are used in the gearboxes in the robots.

Kyodo Yushi TMO 150
Optimol Optigear BM100
Which oil type that is used in the different geaboxes is specified in the oil change
procedures for the specific robot. An overview is found below.
Important: Only specified oil type shall be used.
See also Safety Instructions for Replacing Oil in Gearboxes on page 192.
Temperature
Ambient temperature: Minimum 0C, maximum 70C.
9.7.2 Robot Types Overview

IRB 5500
Axis
Oil type
1-2
Kyodo Yushi TMO 150
3-6
Axis
Oil type
1-4
5-6
Axis
Oil type
1-6
Axis
Oil type
1-6
IRB 52
IRB 5400
IRB 580
3HNA010055-001 en Rev.12
193
IRB 5350 Door Opener

Axis
Oil type
1-2
Kyodo Yushi TMO 150
Trolley axis
Axis
Oil type
Axis
Oil type
1-2
Kyodo Yushi TMO 150
Axis
Oil type
Servo unit
Oil type
E11
E21
T32 Trolley
Compact CBS II
Compact CBS
IRB 5320
Workpiece Positioner
194
3HNA010055-001 en Rev.12
9.8 Grease Type Specifications

Description
The following grease types are used.

Which type to use is specified in the procedures where lubrication is required.
General lubrication grease. Alternatively, Magna Omega 77 may also be used.
Shell Alvania EP2 LF grease
General purpose extreme-pressure industrial grease.
Castrol Optitemp RB1 cable grease
Special cable grease for movable cables.
AOS 340 WC 52055 thermal grease
Non-silicone based thermal grease
Grease, free of products that may react with paint, ie. grease free of silicone,
perfluorinated polyether, etc.
3HNA010055-001 en Rev.12
195
196
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Manual Status
Manual Status
Product manual
IRB 580
3HNA010055-001 en Rev.12
Documents included in manual:
Chp.:
1
2
3
4
5
6
7
7.3
7.4
7.5
7.6
7.7
7.8
8
9
Subject:
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair, Introd. + Releasing brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair, Base unit guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair, Vertical arm guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair, Horizontal arm guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair, Hollow wrist unit guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair, Replacing cable units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair, Calibration fixture installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ABB AS, Robotics

Discrete Automation and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 51489000
ABB Engineering (Shanghai) Ltd.

5 Lane 369, ChuangYe Road
KangQiao Town, PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
www.abb.com/robotics
3HNA010055-001 en Rev.12
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Product Manual Irb580

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Product manual

Product manual, IRB 580

5 Installation and Commissioning

Product manual, IRB 580

Product manual, IRB 580

9.5 Loctite Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product manual, IRB 580

Product manual, IRB 580

Product manual, IRB 580

Product manual, IRB 580

This manual contains information on the following:

This manual should be used during:

Who Should Read This

This manual is intended for:

The reader should:

Product manual, IRB 580

The manual is organized in the following chapters:

Information on function and design of the manipulator.

Specifications for the manipulator, working area drawings,

5. Installation and Commissioning

Information about installation of the manipulator.

Information about maintenance work, including schedules.

Information about repair work, including brake release

General information for decommissioning the manipulator.

Information such as mounting instructions for bearings and

Following manuals are referred to in this manual:

This manual must be read before any work on the robot

Unit Description, Paint

Includes technical description of the units used in the

Unit Description, IRC5P

Includes technical description of the control system

Operators Manual, IRC5P

Includes description of the calibration function and

Technical Reference Manual System Parameters

Includes information on setting of software working

Product manual, IRB 580

substitute for reading the complete Safety Manual.

The following lists some of the most relevant hazards.

Product manual, IRB 580

Following points must be observed before any service work is started:

Product manual, IRB 580

Product manual, IRB 580

Product manual, IRB 580

with procedures given in the Repair chapter in this manual.

Product manual, IRB 580

3.2 Basic Design

Product manual, IRB 580

3.2.2 Component Identification

Standard horizontal arm

Short horizontal arm

Base unit cover

Standard foot unit

Product manual, IRB 580

3.2.3 Purge Air Routing

Flexible hose from

Product manual, IRB 580

3.2.4 Identification Plate

Figure 4 Robot identification plate

PO Box 265, N-4349 Bryne

Product manual, IRB 580

Max. leakage comp.:.......

20Nl/min. (1 bar input)

3.3 The Horizontal Arm