ROBOTICS

Product manual
IRB 360
Trace back information:
Workspace 21A version a12 (not checked in)
Published 2021-03-24 at 09:54:37
Skribenta version 5.4.005
 Product manual
IRB 360 - 1/800
IRB 360 - 1/1130
IRB 360 - 1/1600
IRB 360 - 3/1130
IRB 360 - 6/1600
IRB 360 - 8/1130
IRC5, OmniCore

Document ID: 3HAC030005-001

Revision: Z

© Copyright 2008-2021 ABB. All rights reserved.

Specifications subject to change without notice.
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damage to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

© Copyright 2008-2021 ABB. All rights reserved.

Specifications subject to change without notice.
 Table of contents

Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 16
How to read the product manual ...................................................................................................... 18

1 Safety 19
1.1 Safety information ............................................................................................. 19
1.1.1 Limitation of liability ................................................................................. 19
1.1.2 Requirements on personnel ...................................................................... 20
1.2 Safety signals and symbols ................................................................................. 21
1.2.1 Safety signals in the manual ...................................................................... 21
1.2.2 Safety symbols on manipulator labels ......................................................... 23
1.3 Robot stopping functions .................................................................................... 29
1.4 Installation and commissioning ............................................................................ 30
1.5 Operation ........................................................................................................ 33
1.5.1 Unexpected movement of robot arm ........................................................... 33
1.6 Maintenance and repair ...................................................................................... 34
1.6.1 Maintenance and repair ............................................................................ 34
1.6.2 Emergency release of the robot axes .......................................................... 37
1.6.3 Brake testing .......................................................................................... 38
1.7 Troubleshooting ................................................................................................ 39
1.8 Decommissioning .............................................................................................. 40

2 Installation and commissioning 41

2.1 Introduction to installation and commissioning ....................................................... 41
2.2 Structure manipulator ........................................................................................ 42
2.3 Unpacking ....................................................................................................... 43
2.3.1 Pre-installation procedure ......................................................................... 43
2.3.2 Transport ............................................................................................... 47
2.3.3 Assembling the robot IRB 360 ................................................................... 49
2.3.4 Working range and type of motion .............................................................. 50
2.3.5 The unit is sensitive to ESD ....................................................................... 52
2.4 On-site installation ............................................................................................ 53
2.4.1 Lifting the robot with fork lift ...................................................................... 53
2.4.2 Lifting the robot with roundslings ............................................................... 55
2.4.3 Amount of required space ......................................................................... 57
2.4.4 Orienting and securing the robot frame ....................................................... 58
2.4.5 Orienting and securing the robot ................................................................ 60
2.4.6 Manually releasing the brakes ................................................................... 64
2.4.7 Fitting equipment on robot ........................................................................ 66
2.4.8 Loads .................................................................................................... 72
2.5 Installation of options ......................................................................................... 74
2.5.1 Installation of safety lamp (option 213-1) ...................................................... 74
2.5.2 Installation of (optional) customer connections IRB 360 .................................. 77
2.5.3 Installation of vacuum system (option 218-9) ................................................ 81
2.6 Electrical connections ........................................................................................ 86
2.6.1 Robot cabling and connection points .......................................................... 86
2.7 Start of robot in cold environments ...................................................................... 88

3 Maintenance 89
3.1 Introduction ...................................................................................................... 89
3.2 Maintenance schedule ....................................................................................... 90
3.2.1 Specification of maintenance intervals ........................................................ 90
3.2.2 Regular maintenance ............................................................................... 91
3.2.3 Maintenance schedule IRB 360 .................................................................. 92
3.3 Inspection activities ........................................................................................... 94
3.3.1 Telescopic shaft, axis 4, standard ............................................................... 94

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Table of contents

3.3.2 Telescopic shaft, wash down, axis 4 ........................................................... 96

3.3.3 Telescopic shaft, stainless, axis 4 .............................................................. 98
3.3.4 Vacuum system (optional) ......................................................................... 101
3.3.5 Bar system ............................................................................................. 104
3.3.6 Joint balls .............................................................................................. 108
3.3.7 Upper arms ............................................................................................ 109
3.3.8 Hoses ................................................................................................... 111
3.3.9 Spring units ............................................................................................ 113
3.3.10 Movable plate ......................................................................................... 115
3.3.11 Inspecting information labels ..................................................................... 117
3.4 Replacement/changing activities .......................................................................... 119
3.4.1 Changing the battery in the measuring system ............................................. 119
3.4.2 Changing the telescopic shaft including universal joints ................................. 123
3.5 Lubrication activities .......................................................................................... 125
3.5.1 Type of lubrication in gearboxes ................................................................ 125
3.5.2 Gearboxes, axes 1- 4 ............................................................................... 127
3.6 Cleaning activities ............................................................................................. 136
3.6.1 Introduction ............................................................................................ 136
3.6.2 Standard cleaning ................................................................................... 139
3.6.3 Wash down cleaning ................................................................................ 141
3.6.4 Wash down stainless cleaning ................................................................... 143
3.6.5 Clean room cleaning ................................................................................ 145
3.7 Measuring activities ........................................................................................... 146
3.7.1 Measuring backlash axis 4 ........................................................................ 146

4 Repair 149
4.1 Introduction ...................................................................................................... 149
4.2 General procedures ........................................................................................... 150
4.2.1 Mounting instructions for bearings ............................................................. 150
4.2.2 Mounting instructions for sealings .............................................................. 152
4.2.3 Screw joints .......................................................................................... 155
4.2.4 Cut the paint or surface on the robot before replacing parts ............................ 158
4.3 Complete robot ................................................................................................. 160
4.3.1 Replacement of base cover gasket ............................................................. 160
4.3.2 Replacement of serial measurement board .................................................. 163
4.3.3 Replacement of parallel arms .................................................................... 167
4.3.4 Replacement of upper arm ........................................................................ 172
4.3.5 Replacement of bearing rings .................................................................... 175
4.3.6 Replacement of movable plate ................................................................... 178
4.3.7 Replacement of telescopic shaft ................................................................ 182
4.3.8 Replacement of universal joint ................................................................... 185
4.3.9 Replacement of joint balls ......................................................................... 187
4.3.10 Replacement of gearbox unit 1- 3 ............................................................... 190
4.3.11 Replacement of gearbox unit 4 .................................................................. 194
4.3.12 Replacement of motor axis 1-3 .................................................................. 197
4.3.13 Replacement of motor axis 4 ..................................................................... 202
4.3.14 Replacement of labels .............................................................................. 206
4.3.15 Replacing of calibration marks ................................................................... 209
4.4 Vacuum system ................................................................................................ 211
4.4.1 Replacement of vacuum hoses .................................................................. 211
4.4.2 Draining of water separation filter ............................................................... 214
4.4.3 Replacement of ejector unit ....................................................................... 216
4.5 Cable harness .................................................................................................. 220
4.5.1 Replacement of cable harness ................................................................... 220
4.5.2 Replacement of brake release button .......................................................... 223

5 Calibration information 227

5.1 When to calibrate ............................................................................................. 227
5.2 Calibration method ............................................................................................ 228

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 Table of contents

5.3 Calibration movement directions for all axes .......................................................... 230

5.4 Synchronization marks and synchronization position for axes ................................... 231
5.5 Calibrating axis 1-3 ............................................................................................ 232
5.6 Calibrating axis 4 .............................................................................................. 236
5.7 Fine calibration procedure on FlexPendant ............................................................ 238
5.8 Updating revolution counters ............................................................................... 241
5.9 Checking the synchronization position .................................................................. 245

6 Decommissioning 249
6.1 Introduction ...................................................................................................... 249
6.2 Environmental information .................................................................................. 250
6.3 Scrapping of robot ............................................................................................. 252

7 Reference information 253

7.1 Introduction ...................................................................................................... 253
7.2 Applicable standards ......................................................................................... 254
7.3 Unit conversion ................................................................................................. 256
7.4 Weight specifications ......................................................................................... 257
7.5 Standard toolkit ................................................................................................ 258
7.6 Special tools .................................................................................................... 259
7.7 Lifting accessories and lifting instructions .............................................................. 260
7.8 Grease specification .......................................................................................... 261

8 Spare part lists 267

8.1 Spare part lists and illustrations ........................................................................... 267

Index 269

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 Overview of this manual

Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical installation of the IRB 360
• maintenance of the IRB 360
• mechanical and electrical repair of the IRB 360
The robot described in this manual has the following protection types:
• Standard
• Clean Room
• Wash

Usage
This manual should be used during:
• installation and commissioning, from lifting the product to its work site and
securing it to the foundation, to making it ready for operation
• maintenance work
• repair work
• decommissioning work

Note

It is the responsibility of the integrator to conduct a hazard and risk analysis of

the final application and to ensure its safety.
It is the responsibility of the integrator to provide safety and user guides for the
robot system.

Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.

Prerequisites
A maintenance/repair/installation craftsman working with an ABB robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.

Product manual scope

The manual covers all variants and designs of the IRB 360. Some variants and
designs may have been removed from the business offer and are no longer available
for purchase.

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References

Tip

All documents can be found via myABB Business Portal, www.abb.com/myABB.

IRC5

Reference Document ID
Product manual, spare parts - IRB 360 3HAC049101-
001
Circuit diagram - IRB 360 3HAC028647-
009
Product specification - IRB 360 3HAC029963-
001
Safety manual for robot - Manipulator and IRC5 or OmniCore controller i 3HAC031045-
001
Product manual - IRC5 3HAC021313-
IRC5 with main computer DSQC 639. 001

Product manual - IRC5 3HAC047136-

IRC5 with main computer DSQC1000. 001

Circuit diagram - IRC5 3HAC024480-

011
Product manual - IRC5 Compact 3HAC035738-
IRC5 with main computer DSQC 639. 001

Product manual - IRC5 Compact 3HAC047138-

IRC5 with main computer DSQC1000. 001

Circuit diagram - IRC5 Compact 3HAC049406-

003
Product manual - IRC5 Panel Mounted Controller 3HAC027707-
IRC5 with main computer DSQC 639. 001

Product manual - IRC5 Panel Mounted Controller 3HAC047137-

IRC5 with main computer DSQC1000. 001

Circuit diagram - IRC5 Panel Mounted Controller 3HAC026871-

020
Circuit diagram - Euromap 3HAC024120-
004
Operating manual - IRC5 with FlexPendant 3HAC050941-
001
Operating manual - Calibration Pendulum 3HAC16578-1
Operating manual - Service Information System 3HAC050944-
001
Application manual - Additional axes and stand alone controller 3HAC051016-
001
Application manual - Controller software IRC5 3HAC050798-
001
Technical reference manual - Lubrication in gearboxes 3HAC042927-
001

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Continued

Reference Document ID
Technical reference manual - System parameters 3HAC050948-
001
Application manual - Electronic Position Switches 3HAC050996-
001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.

OmniCore

Reference Document ID
Product manual, spare parts - IRB 360 3HAC049101-
001
Circuit diagram - IRB 360 3HAC028647-
009
Product specification - IRB 360 3HAC029963-
001
Safety manual for robot - Manipulator and IRC5 or OmniCore controller i 3HAC031045-
001
Product manual - OmniCore C30 3HAC060860-
001
Operating manual - OmniCore 3HAC065036-
001
Application manual - Controller software OmniCore 3HAC066554-
001
Technical reference manual - Lubrication in gearboxes 3HAC042927-
001
Technical reference manual - System parameters 3HAC065041-
001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.

Revisions

Revision Description
- First edition
A This revision includes the following additions and/or changes:
• Section What is an emergency stop? added to chapter Safety.
• Section Maintenance schedule: Interval for replacement of battery
pack changed.
B This revision includes the following additions and/or changes:
• Implementation of IRB 360 1/1600.

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Continued

Revision Description
C This revision includes the following additions and/or changes:
• Chapter Maintenance sections Regular maintenance on page 91,
Telescopic shaft, axis 4, standard on page 94, Telescopic shaft, wash
down, axis 4 on page 96, Telescopic shaft, stainless, axis 4 on page 98
and Bar system on page 104 updated concerning collisions.
• Chapter Maintenance section Bar system on page 104 updated on how
to measure the distance between the bearing holders.
• Circuit diagrams are not included in this document but delivered as
separate files.
• List of standards updated, see Applicable standards on page 254.
• Spare parts chapter - art. no. updated for telescopic shaft and upper
arm.
Updates in the chapter Safety:
• Updated safety signal graphics for the levels Danger and Warning,
see Safety signals in the manual on page 21.
• New safety labels on the manipulators, see Safety symbols on manip-
ulator labels on page 23.
• Revised terminology: robot replaced with manipulator.
D This revision includes the following additions and/or changes:
• Minor updates in the chapter Calibration.
E This revision includes the following additions and/or changes:
• Added caution regarding swivel cup, see Fitting equipment on robot
on page 66.
• Updated instructions for cleaning, see Cleaning activities on page 136.
• Updated tightening sequence, see Replacement of base cover gasket
on page 160.
• Updated refitting instruction, see Replacement of brake release button
on page 223.
• Added information about when to update resolver values, see When
to calibrate on page 227.
• Updated information in Environmental information on page 250.
• Updated spare parts, see Spare parts in the base.
F This revision includes the following updates:
• A new block, about general illustrations, added in section How to read
the product manual on page 18.
• New Option 864-1 connection FB7 on robot base.
G This revision includes the following updates:
• Spare part number for the telescopic shaft (1600) is corrected, see
Spare parts - telescopic shaft.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 155.
• Maintenance interval regarding replacement of the telescopic shaft is
changed from 8,000 hours to 4,000 hours, see Maintenance schedule
IRB 360 on page 92.
• Added information about batteries.

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Revision Description
H This revision includes the following updates:
• Variant IRB 360 - 8/1130 is added to the manual.
• Information about type and volume of oil in gearboxes is removed
from the manual, and is instead now available in the Technical refer-
ence manual - Lubrication in gearboxes - 3HAC042927-001. More in-
formation in section Type of lubrication in gearboxes on page 125.
• Added Cut the paint or surface on the robot before replacing parts on
page 158.
• Added information about an alternative bearing ring, see Spare parts
and Bar system on page 104.
• A new SMB unit and battery is introduced, with longer battery lifetime.
• New article numbers for set screws, see Spare parts, telescopic shafts.
• Corrected directions in figure for calibration movement and jogging
directions, see Calibration movement directions for all axes on
page 230.
J This revision includes the following updates:
• Variant IRB 360 - 6/1600 is added to the manual.
• Corrected the protection class for protection typ Standard, see Protec-
tion classes on page 46.
• Changed the tightening torque, see Replacement of motor axis 4 on
page 202.
• Added information about visual difference between bearing ring ver-
sions, see Different versions of bearing rings require different main-
tenance procedures on page 104.
• Universal joint 3HAC028132-001 is replaced with 3HAC046664-001,
see Spare parts - telescopic shafts.
K This revision includes the following updates:
• Illustrations of placement of labels updated.
• Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 252.
• Spare parts and exploded views are not included in this document
but delivered as a separate document. See Product manual, spare
parts - IRB 360.
• Mechanical interface of IRB 360 - 8/1130 and IRB 360 - 6/1600 updated.
L This revision includes the following updates:
• Added information in calibration chapter, see Using the jogging window
on the FlexPendant on page 245.
• Clarification made about when to choose standard calibration vs. ring
calibration, see Types of calibration on page 228.
• Clarification made about measured distance between bearing holders,
regarding wear on bearing rings, see Distance between bearing
holders on page 106.
• Minor corrections
M This revision includes the following updates:
• Updated instructions for cleaning, see Cleaning activities on page 136.
• Minor corrections
N This revision includes the following updates:
• Minor corrections

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Continued

Revision Description
P Published in release R16.2. The following updates are done in this revision:
• Corrections due to updates in terminology.
• Warning about high center of gravity during transport added.
• Updates about parameter Calibration Position (cal_position) in Calib-
ration information on page 227.
• Added information about tightening torque in section Replacement of
movable plate on page 178.
Q Published in release R17.1. The following updates are done in this revision:
• Major updates in cleaning section.
• Updates regarding checking the calibration position.
• Measurement method in Maintenance added.
R Published in release R17.2. The following updates are done in this revision:
• Caution about removing metal residues added in sections about SMB
boards.
• Updated list of applicable standards.
• Changed torque on oil plug (Gear-motor unit axis 4).
• Section Start of robot in cold environments on page 88 added.
• Updated figure on motor axis 4.
• Added a note in the instruction Removal on page 188.
• Updated maintenance schedule with sealing ring (v-ring) and the af-
fected cleaning instructions.
• Updated information regarding extra load mass.
S Published in release R18.1. The following updates are done in this revision:
• Safety restructured.
• Updated information regarding extra load mass.
• Added sections in General procedures on page 150.
• Minor update of graphics in the calibration chapter.
• Information about myABB Business Portal added.
T Published in release R18.2. The following updates are done in this revision:
• Added section for inspection of labels in maintenance chapter.
• Grease article number updated (is 3HAC042560-001, was
3HAC029132-001)
U Published in release R18.2. The following updates are done in this revision:
• Reference updated.
V Published in release 19B. The following updates are made in this revision:
• New touch up color Graphite White available. See Cut the paint or
surface on the robot before replacing parts on page 158.
W Published in release 19D. The following updates are made in this revision:
• Sealing compound Sikaflex 521 FC replaced by Trans7 from Trans
Clear.
• Requirement to paint touch up color on refitted joints sealed with
Trans7 is removed.
X Published in release 20A. The following updates are made in this revision:
• Changed the repair procedure for replacing parallel arms.
• Clarified and added information in mounting instructions for rotating
sealings, see Mounting instructions for sealings on page 152.
Y Published in release 20C. The following updates are made in this revision:
• Updated information regarding the fact that installation instructions
no longer are enclosed with bearing rings 3HAC2091-1, see Different
versions of bearing rings require different maintenance procedures
on page 104.

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Revision Description
Z Published in release 21A. The following updates are made in this revision:
• Added information on supporting OmniCore controller.
• Added image showing distance between bearing holders on IRB 360
WDS, see Distance between bearing holders on page 106.
• Corrected image of calibration marks location, see Replacing of calib-
ration marks on page 209.
• Updated the instruction Manually releasing the brakes on page 64.
• Size of grease nipple on telescopic shaft clarified, see Telescopic
shaft, stainless, axis 4 on page 98.

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Product documentation

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.

Tip

All documents can be found via myABB Business Portal, www.abb.com/myABB.

Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.

Technical reference manuals

The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.

Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.

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Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.

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How to read the product manual

How to read the product manual

Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.

References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.

References to required equipment

The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Action Note/Illustration
3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.

Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 19.

Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.

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 1 Safety
1.1.1 Limitation of liability

1 Safety
1.1 Safety information

1.1.1 Limitation of liability

Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.

Spare parts and equipment

ABB supplies original spare parts and equipment which have been tested and
approved. The installation and/or use of non-original spare parts and equipment
can negatively affect the safety, function, performance, and structural properties
of the robot. ABB is not liable for damages caused by the use of non-original spare
parts and equipment.

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1 Safety
1.1.2 Requirements on personnel

1.1.2 Requirements on personnel

General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.

Personal protective equipment

Use personal protective equipment, as stated in the product manual.

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 1 Safety
1.2.1 Safety signals in the manual

1.2 Safety signals and symbols

1.2.1 Safety signals in the manual

Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.

Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
For more information, see standard ISO 13849.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.

WARNING Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in serious
injury.

ELECTRICAL Signal word used to indicate a potentially hazardous

SHOCK situation related to electrical hazards which, if not
avoided, could result in serious injury.

CAUTION Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in slight
injury.

ELECTROSTATIC Signal word used to indicate a potentially hazardous

DISCHARGE (ESD) situation which, if not avoided, could result in severe
damage to the product.

NOTE Signal word used to indicate important facts and

conditions.

Continues on next page

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1 Safety
1.2.1 Safety signals in the manual
Continued

Symbol Designation Significance

TIP Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.

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 1 Safety
1.2.2 Safety symbols on manipulator labels

1.2.2 Safety symbols on manipulator labels

Introduction to symbols
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.

Note

The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.

Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 23.
The information labels can contain information in text.

Symbols on safety labels

Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.

xx0900000839

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1 Safety
1.2.2 Safety symbols on manipulator labels
Continued

Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813

Before disassembly, see product manual

xx0900000816

Do not disassemble
Disassembling this part can cause injury.

xx0900000815

Extended rotation
This axis has extended rotation (working area) compared to
standard.

xx0900000814

Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808

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 1 Safety
1.2.2 Safety symbols on manipulator labels
Continued

Symbol Description
Tip risk when loosening bolts
The robot can tip over if the bolts are not securely fastened.

xx0900000810

xx1500002402

Crush
Risk of crush injuries.

xx0900000817

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1 Safety
1.2.2 Safety symbols on manipulator labels
Continued

Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)

xx0900000818

!
3HAC 4431-1/06

xx1300001087

Moving robot
4 6 The robot can move unexpectedly.
3 5

1
xx0900000819

xx1000001141

2 3

xx1500002616

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 1 Safety
1.2.2 Safety symbols on manipulator labels
Continued

Symbol Description
Brake release buttons

xx0900000820

xx1000001140

Lifting bolt

xx0900000821

Chain sling with shortener

xx1000001242

Lifting of robot

xx0900000822

Oil
Can be used in combination with prohibition if oil is not allowed.

xx0900000823

Mechanical stop

xx0900000824

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1 Safety
1.2.2 Safety symbols on manipulator labels
Continued

Symbol Description
No mechanical stop

xx1000001144

Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.

xx0900000825

Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.

xx0900000826

Shut off with handle

Use the power switch on the controller.

xx0900000827

Do not step
Warns that stepping on these parts can cause damage to the
parts.

xx1400002648

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 1 Safety
1.3 Robot stopping functions

1.3 Robot stopping functions

Protective stop and emergency stop

The protective stops and emergency stops are described in the product manual
for the controller.
For more information see:
• Product manual - OmniCore C30
• Product manual - IRC5
• Product manual - IRC5 Compact
• Product manual - IRC5 Panel Mounted Controller

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1 Safety
1.4 Installation and commissioning

1.4 Installation and commissioning

National or regional regulations

The integrator of the robot system is responsible for the safety of the robot system.
The integrator is responsible that the robot system is designed and installed in
accordance with the safety requirements set forth in the applicable national and
regional standards and regulations.
The integrator of the robot system is required to perform an assessment of the
hazards and risks.

Layout
The robot integrated to a robot system shall be designed to allow safe access to
all areas during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing
the working area.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand
the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum
speed.
• The maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed
in the section Robot motion in the product specification for the respective
manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall be considered.
Consider hazards from other equipment in the robot system, for example, that
guards remain active until identified hazards are reduced to an acceptable level.

Allergenic material
See Environmental information on page 250 for specification of allergenic materials
in the product, if any.

Securing the robot to the foundation

The robot must be properly fixed to its foundation/support, as described in the
product manual.
When the robot is installed at a height, hanging, or other than mounted directly on
the floor, there will be additional hazards.

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1.4 Installation and commissioning
Continued

Electrical safety
The mains power must be installed to fulfill national regulations.
The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.
Wherever possible, power on/off or rebooting the robot controller shall be performed
with all persons outside the safeguarded space.

Note

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.

Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.

Other hazards

WARNING

Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.

WARNING

Manipulator movements can cause serious injuries on users and may damage
equipment.
The risk assessment should also consider other hazards arising from the
application, such as, but not limited to:
• Water
• Compressed air
• Hydraulics

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1 Safety
1.4 Installation and commissioning
Continued

Pneumatic or hydraulic related hazards

Note

The pressure in the complete pneumatic or hydraulic systems must be released

before service and maintenance.
All components in the robot system that remain pressurized after switching off
the power to the robot must be marked with clearly visible drain facilities and a
warning sign that indicates the hazard of stored energy.
Loss of pressure in the robot system may cause parts or objects to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.

Verify the safety functions

Before the robot system is put into operation, verify that the safety functions are
working as intended and that any remaining hazards identified in the risk
assessment are mitigated to an acceptable level.

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 1 Safety
1.5.1 Unexpected movement of robot arm

1.5 Operation

1.5.1 Unexpected movement of robot arm

Unexpected movement of robot arm

WARNING

Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.

WARNING

Manipulator movements can cause serious injuries on users and may damage
equipment.

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1 Safety
1.6.1 Maintenance and repair

1.6 Maintenance and repair

1.6.1 Maintenance and repair

General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Hazards due to stored mechanical energy in the manipulator for the purpose of
counterbalancing axes must be considered before maintenance or repair.
Never use the robot as a ladder, which means, do not climb on the controller,
manipulator, including motors, or other parts. There are hazards of slipping and
falling. The robot might be damaged.
Make sure that there are no loose screws, turnings, or other unexpected parts
remaining after work on the robot has been performed.
When the work is completed, verify that the safety functions are working as
intended.

Hot surfaces
Surfaces can be hot after running the robot. Touching the surfaces may result in
burns.
Allow the parts to cool down before maintenance or repair.

Allergic reaction

Warning Description Elimination/Action

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.

Allergic reaction

Gearbox lubricants (oil or grease)

When handling oil, grease, or other chemical substances the safety information of
the respective manufacturer must be observed.

Note

Take special care when handling hot lubricants.

Warning Description Elimination/Action

Changing and draining gearbox Make sure that protective gear
oil or grease may require hand- like goggles and gloves are al-
ling hot lubricant heated up to ways worn during this activity.
90 °C.
Hot oil or grease

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 1 Safety
1.6.1 Maintenance and repair
Continued

Warning Description Elimination/Action

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.

Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox
Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Al-
ways use the type of oil specified
for the product.
Do not mix types of oil
Warm oil drains quicker than Run the robot before changing
cold oil. the gearbox oil, if possible.

Heat up the oil

The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume
For lifetime reasons always drain
as much oil as possible from the
gearbox. The magnetic oil plugs
will gather residual metal chips.

Contaminated oil in
gearboxes

Hazards related to batteries

Under rated conditions, the electrode materials and liquid electrolyte in the batteries
are sealed and not exposed to the outside.

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1 Safety
1.6.1 Maintenance and repair
Continued

There is a hazard in case of abuse (mechanical, thermal, electrical) which leads

to the activation of safety valves and/or the rupture of the battery container. As a
result under certain circumstances, electrolyte leakage, electrode materials reaction
with moisture/water or battery vent/explosion/fire may follow.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Operating conditions on page 46.
See safety instructions for the batteries in Material/product safety data
sheet - Battery pack (3HAC043118-001).

Unexpected movement of robot arm

WARNING

Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.

WARNING

Manipulator movements can cause serious injuries on users and may damage
equipment.

Related information
See also the safety information related to installation and operation.

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 1 Safety
1.6.2 Emergency release of the robot axes

1.6.2 Emergency release of the robot axes

Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
• Manually releasing the brakes on page 64.
The robot may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.

Increased injury
Before releasing the brakes, make sure that the weight of the manipulator does
not result in additional hazards, for example, even more severe injuries on a trapped
person.

DANGER

When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways.
Make sure no personnel is near or beneath the robot.

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1 Safety
1.6.3 Brake testing

1.6.3 Brake testing

When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.

How to test
The function of the holding brake of each axis motor may be verified as described
below:
1 Run each axis to a position where the combined weight of the manipulator
and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the manipulator does not change position as the motors are switched off,
then the brake function is adequate.

Note

For robots with the option SafeMove, the Cyclic Brake Check routine is
recommended. See the manual for SafeMove in References on page 10.

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 1 Safety
1.7 Troubleshooting

1.7 Troubleshooting

General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.

DANGER

Troubleshooting on the controller while powered on must be performed by

personnel trained by ABB or by ABB field engineers.
A risk assessment must be done to address both robot and robot system specific
hazards.

WARNING

Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.

WARNING

Manipulator movements can cause serious injuries on users and may damage
equipment.

Related information
See also the safety information related to installation, operation, maintenance, and
repair.

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1 Safety
1.8 Decommissioning

1.8 Decommissioning

General
See section Decommissioning on page 249.

Unexpected movement of robot arm

WARNING

Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.

WARNING

Manipulator movements can cause serious injuries on users and may damage
equipment.

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 2 Installation and commissioning
2.1 Introduction to installation and commissioning

2 Installation and commissioning

2.1 Introduction to installation and commissioning

General
This chapter contains assembly instructions and information for installing the IRB
360 controller at the working site.
See also the product manual for the robot controller.
The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.

Safety information
Before any installation work is commenced, 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 the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any installation
work.

Note

If the IRB 360 is connected to power, always make sure that the robot is
connected to protective earth and a residual current device (RCD) before starting
any installation work.
For more information see:
• Product manual - OmniCore C30
• Product manual - IRC5
• Product manual - IRC5 Compact
• Product manual - IRC5 Panel Mounted Controller

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2 Installation and commissioning
2.2 Structure manipulator

2.2 Structure manipulator

Manipulator structure
The figure shows the manipulator structure and components.

xx0700000451

A Upper arm axis 1

B Upper arm axis 2
C Upper arm axis 3
D Axis-4 motor
E SMB unit
F Telescopic shaft axis 4
G Parallel arm
H Movable plate
I Vacuum kit (optional)
J Medium house set (optional)
K Large house set (optional)

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 2 Installation and commissioning
2.3.1 Pre-installation procedure

2.3 Unpacking

2.3.1 Pre-installation procedure

General
This instruction is primarily intended for use when unpacking and installing the
robot for the first time. It also contains information useful during later re-installation
of the robot.

Checking the pre-requisites for installation

The check-list below details what must be observed before proceeding with the
actual installation of the robot:

Note

Read and follow these instructions before installation of the robot.

Action Detailed in section:

1 Make sure only qualified installation person-
nel conforming to all national and local codes
are allowed to perform the installation.
2 Make sure the robot has not been damaged, Check especially following items:
by visually inspecting its exterior. • Composite arms (upper arms and
bar system); no hacks
• Joint balls; no scratches
• Ventilation hose; no holes
3 Make sure the lifting accessory to be used .
is dimensioned to handle the weight of the
robot.
4 If the robot is not to be installed directly, it
must be stored.
5 Make sure the appointed operating environ-
ment of the robot conforms to the specifica-
tions.
6 Before taking the robot to its installation site,
make sure the site conforms to applicable
requirements.
7 Before moving the robot, make sure it does
not tip over!
8 When these prerequisites have been met, For assemble of the robot, see section
the robot may be taken to its installation site. Assembling the robot IRB 360 on
page 49

Weight
The following table shows the weight of the robot model.
Robot model Weight
Standard 120 kg (264.5 pounds)
Wash-Down (WD) 120 kg (264.5 pounds)

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2.3.1 Pre-installation procedure
Continued

Robot model Weight

Wash-Down stainless (WDS) 145 kg (319.6 pounds)

Note

The stainless version is not available for the IRB 360 used with OmniCore
controllers.

Loads on foundation
The following tables show the various forces and torques working on the robot
during different kinds of operation.
See figure below the tables.

Robot version IRB 360 - 1/800, IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/1600

Force N Max. load in operation

Fx ±330 N
Fy ±260 N
Fz -1500 ±170 N

Torque Nm Max. load in operation

Mx ±200 Nm
My ±230 Nm
Mz ±100 Nm

Robot version IRB 360 - 8/1130, IRB 360 - 6/1600

Force N Max. load in operation

Fx ±550 N
Fy ±500 N
Fz -1500 ±460 N

Torque Nm Max. load in operation

Mx ±380 Nm
My ±440 Nm
Mz ±180 Nm

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 2 Installation and commissioning
2.3.1 Pre-installation procedure
Continued

Illustration

en0900000413

The three support points of the manipulator base box shall be mounted against
three flat surfaces within the specification above. Shims is used if necessary.

Requirements, foundation
The following subsections show the requirements for the foundation regarding
stiffness and forces.

Stiffness of robot frame

The stiffness of the robot frame must be designed to minimize the influence on the
dynamic behavior of the robot. It is recommended that a frame with a lowest natural
frequency (with the robot mounted in the frame) higher than 17 Hz is used for robot
versions IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600 and
a frame with a lowest natural frequency higher than 40 Hz is used for robot version
IRB 360 - 8/1130, IRB 360 - 6/1600. TuneServo can be used for adapting the robot
tuning to a non-optimal foundation.

Forces
Maximum force in each fixing point are 500 N referring to the z-direction in the
base coordinate system, regarding coordinate system see Product
specification - IRB 360. A robot frame is not included in the delivery.

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2.3.1 Pre-installation procedure
Continued

Storage conditions
The following table shows the allowed storage conditions for the robot.
Parameter Value
If the equipment is not going to be installed -25°C to +55°C
straight away, it must be stored in a dry area
at an ambient temperature between.

Operating conditions
The following table shows the allowed operating conditions for the robot.
Parameter Value
Ambient temperature 0°C to +45°C.
Relative humidity Max. 95% at constant temperature

Protection classes
The following table shows the protection class of the robot.
Equipment Protection class
Standard (Std.) IP54
Wash-Down (WD) IP67
Wash-Down Stainless (WDS) IP69K
Clean Room, Stainless Clean Room IP54

Note

The stainless version is not available for the IRB 360 used with OmniCore
controllers.

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 2 Installation and commissioning
2.3.2 Transport

2.3.2 Transport

General
This section describes how to transport the manipulator.

Note

The transport shall be made by qualified personnel and should conform to all
national and local codes.

Transport position
Whenever the manipulator is transported, it must be in mounting position. It is not
allowed to turn the manipulator up side down.
When air transport is used, the robot must be located in a pressure-equalized area.

WARNING

The center of gravity for IRB 360 during transport is very high, 804-810 mm from
the bottom. It might tilt and fall when carried on a forklift.

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2 Installation and commissioning
2.3.2 Transport
Continued

xx0700000434

A Robot delivery box

B Securing point x3
C Robot delivery note

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 2 Installation and commissioning
2.3.3 Assembling the robot IRB 360

2.3.3 Assembling the robot IRB 360

Overview
Follow these steps to assemble the robot after unpacking.

Assembling the robot

Action Note
1 Prepare the working site according to Amount of required space on page 57
sections: Orienting and securing the robot frame on
page 58.
2 Lift the robot according to instructions Lifting the robot with fork lift on page 53.
in sections: Lifting the robot with roundslings on page 55.
Pre-installation procedure on page 43
3 Secure the robot according to section: Orienting and securing the robot on page 60.
4 Assemble the parallel arms according Replacement of parallel arms on page 167.
to section:
5 Assemble the telescopic shaft accord- Replacement of telescopic shaft on page 182.
ing to section:
6 Assemble the movable plate according Replacement of movable plate on page 178.
to section:
7 Connect the controller and the manip- Robot cabling and connection points on
ulator. page 86.

CAUTION

Before mounting external equipment on the robot, first read the section Fitting
equipment on robot on page 66.

Assembly options
To facilitate cleaning, it is possible to use the spring units without the rubber
bellows, if that is preferred due to hygienic or other reasons.

xx0700000707

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2 Installation and commissioning
2.3.4 Working range and type of motion

2.3.4 Working range and type of motion

Motion pattern

+Y
B

-
-

A +X
C
+
+

+Z

- +
D
xx0700000448

A Axis 1
B Axis 2
C Axis 3
D Axis 4

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2.3.4 Working range and type of motion
Continued

Working range

xx0700000473

Robot variant Measurement A Diameter B Diameter C Measurement D

IRB 360 - 1/1130 250 mm 1130 mm 967 mm 50 mm
IRB 360 - 3/1130 250 mm 1130 mm 967 mm 50 mm
IRB 360 - 1/800 200 mm 800 mm - -
IRB 360 - 1/1600 300 mm 1600 mm 1440 mm 50 mm
IRB 360 - 6/1600 305 mm 1600 mm 1200 mm 155 mm
IRB 360 - 8/1130 250 mm 1130 mm 750 mm 100 mm

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2.3.5 The unit is sensitive to ESD

2.3.5 The unit is sensitive to ESD

Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.

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

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2.4.1 Lifting the robot with fork lift

2.4 On-site installation

2.4.1 Lifting the robot with fork lift

WARNING

Never walk under a suspended load!

Lifting position

xx0700000434

A Robot package top

B Robot package securing point x3
C Delivery note

Recommended equipment

Equipment Art.no. Note

Fork lift

Continues on next page

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2.4.1 Lifting the robot with fork lift
Continued

Lifting the robot

Action Note
1
CAUTION

The delivery package weighs 200 kg! All lifting ac-

cessories used must be sized accordingly.

2 Lift the robot package to the installation site.

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2.4.2 Lifting the robot with roundslings

2.4.2 Lifting the robot with roundslings

WARNING

Never walk under a suspended load!

The best way to lift the manipulator is to use lifting straps and a traverse crane.
The lifting strap dimensions must comply with the applicable standards for lifting.

Lifting position

xx0700000433

A L= 500 mm (20 inch)

Recommended equipment

Equipment Art.no. Note

Roundslings

Continues on next page

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2.4.2 Lifting the robot with roundslings
Continued

Lifting the robot with roundslings

Action Note
1 Attach the roundslings to the robot base
box, see figure Lifting position on page 55.

CAUTION

The IRB 360 weighs 120 kg (Std) and 145

kg (WDS). All lifting accessories used
must be sized accordingly.

xx0700000466

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2.4.3 Amount of required space

2.4.3 Amount of required space

Required space
The following figure shows the required amount of space to operate the manipulator.

xx0700000489

Dimensions

Variant A (mm) B (mm) C (mm) D (mm) E (mm) F (mm) G (mm) H (mm)

IRB 360 - 1/1130 1115 865 647 370 275 389.5 28.50 R366
IRB 360 - 3/1130
IRB 360 - 8/1130 1142 892 650 370 275 389.5 28.50 R366
IRB 360 - 1/800 1160 960 481 370 275 R251
IRB 360 - 1/1600 1412 1112 880 370 275 438 95 R447
IRB 360 - 6/1600 1412.5 1107.5 883 370 275 478.9 148.3 R515

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2.4.4 Orienting and securing the robot frame

2.4.4 Orienting and securing the robot frame

General
This section details how to orient and secure the robot frame at a horizontal level
at the installation site in order to run the robot safely.

WARNING

Make sure that the robot frame is secured before mounting the robot.

Illustration

xx0700000469

A Spirit level
B Chemical or mechanical expander bolts
C Shim

Continues on next page

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2.4.4 Orienting and securing the robot frame
Continued

Required equipment and references

Equipment Spare part no. Note

Spirit level
Shim Shim drawing on page 59
Chemical bolts or mechanical
expanding bolts.
Standard tools Standard toolkit on page 258

References
Pre-installation procedure on page 43

Orienting and securing

Action Note
1 Make sure the installation site for the robot con-
forms to the specifications in section Pre-installation
procedure on page 43.
2 Prepare the installation site.
3 Use a water level to level the robot frame. Use shim for leveling. Example of
shim shown in Shim drawing on
page 59
4 Secure the robot frame to the floor. Use chemical or mechanical ex-
pander bolts.

Shim drawing
Example of shim.

xx0700000623

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2.4.5 Orienting and securing the robot

2.4.5 Orienting and securing the robot

General
This section describes how to orient and secure the robot at a horizontal level at
the installation site.

Illustration

xx0700000444

A Screw M12
B Bonded seal washer, rubber/metal
C Spacer, metal
D Washer, EPDM-rubber compressed 50%.

Required equipment

Equipment, etc. Spare part no. Note

Standard tools Standard toolkit on page 258

Continues on next page

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2.4.5 Orienting and securing the robot
Continued

Hole configuration, base

xx0700000467

The three support points of the manipulator base box shall be mounted against
three flat surfaces with a flatness within the specification. Use shims if necessary.

Continues on next page

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2.4.5 Orienting and securing the robot
Continued

Attachment bolts, specification

Ø32

xx0700000522

A Screw M12
B Bonded seal washer, rubber/metal.
C Spacer, metal
D Washer, EPDM-rubber compressed 50%.
E Robot frame
F Bracket

Attachments Dimensions
Attachment bolts, 3 pcs. M12x (50)
The length of the screws depend
on the design of the robot frame
Bonded seal washer, rubber/metal, 3 pcs.

Continues on next page

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2.4.5 Orienting and securing the robot
Continued

Attachments Dimensions
Washer, EPDM-rubber compressed 50%, 3 pcs. Illustration on page 60
Spacer, metal, 3 pcs. Illustration on page 60

Orienting and securing

Action Note
1 Make sure the installation site for the
robot conforms to the specifications in
section Pre-installation procedure on
page 43.
2 Prepare the installation site. Detailed in section Orienting and securing the
robot frame on page 58
3 Lift the robot to the installation site. Detailed in section Lifting the robot with fork
lift on page 53 and in section Lifting the robot
with roundslings on page 55
4
Note

If use of ABB’s vacuum system is inten-

ded, make sure there is a space left for
the bracket (F).

5 Fit and tighten the bolts and washers The screw joint must be able to withstand the
in the base attachment holes. stress loads defined in section Pre-installation
procedure on page 43.

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2.4.6 Manually releasing the brakes

2.4.6 Manually releasing the brakes

DANGER

Releasing the brakes is a hazardous action that may cause injury and damage
property. It must be done with great care and only when absolutely necessary.

General
This section describes how to release the holding brakes.
The brake release button is located on the base of the robot, close to the center.

Using the brake release unit when the robot is connected to the robot controller
This procedure details how to release the holding brakes with push-buttons, when
the robot is connected to the controller.
Action Note
1 The internal brake release unit is located
at the base of the robot.

xx0700000435

A Brake release button

2 Press and hold the brake release button
(keep it pressed in). The brake will func-
tion again as soon as the button is re-
leased.

Continues on next page

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2.4.6 Manually releasing the brakes
Continued

Using the brake release unit with an external power supply

This section describes how to release the holding brakes with the internal brake
release unit, using an external voltage supply. This is done if the robot is not
connected to the controller.

xx0700000441

Note

Be careful not to interchange the 24 V and 0 V pins. If they are mixed-up,

electrical components can be damaged.

Action Note
1 Connect an external power +24V supply to the FCI See cable harness in Spare parts
connector (pin 13 to 0V and pin 15 to +24V). - cable harness.
2 Press and hold the brake release button (keep it
pressed in). The brake will function again as soon
as the button is released.

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2.4.7 Fitting equipment on robot

2.4.7 Fitting equipment on robot

Overview
This section describes how to fit equipment on the IRB 360.

Note

All equipment and cables used on the robot, must be designed and fitted not to
damage the robot and/or its parts.

Continues on next page

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2.4.7 Fitting equipment on robot
Continued

Mechanical interface
STD - IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600

xx0700000471

A Free space, depth 6 mm

B R1/4”
C Ø14 H8 depth 4 mm
D Key grip = width 22 mm height 5.5 mm
E Ø25 h8 depth 6 mm

Continues on next page

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2.4.7 Fitting equipment on robot
Continued

3D - IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600

xx0700000709

Continues on next page

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2.4.7 Fitting equipment on robot
Continued

IRB 360 - 8/1130, IRB 360 - 6/1600

3x 120°

°
60 10 57.5
96

10

6H7
+0.2
3x 6.6 0

25H8
50 h8
4x M6 10 6

40
45°

4x 90°
xx1300000170

Required equipment

Equipment Article number Note

Standard tools - Standard toolkit on page 258
Open end spanner - 22 mm

Mounting equipment R1/4” on movable plate with swivel

CAUTION

Never drill a hole in the manipulator without first consulting maintenance/repair

personnel or the design department at ABB.

CAUTION

Never remove the swivel cup. The cup protects the bearings.

Action Note
1 Attach the tool to the mounting flange. Fitting R1/4”

Continues on next page

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2.4.7 Fitting equipment on robot
Continued

Action Note
2
CAUTION

If the movable plate is equipped with a

swivel:
Always use an open-end spanner 22 m
or similar on the mounting flange, when
tightening.

xx0700000490

A Mounting flange
B Tool (fitting R1/4”)
C Open-end spanner 22 mm

3
Note

If axial tool movement using axis 4 is in-

tended, use a locking liquid or a lock
screw to prevent rotation of tool.
If a high frequent use of linear tool move-
ment is intended, use a tool with mounting
flange.

Continues on next page

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2.4.7 Fitting equipment on robot
Continued

Mounting equipment to flange on movable plate with swivel

IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600

xx0700000523

A 4 pcs Screws M4

Action Note
1 Attach the tool to the mounting flange.
2
CAUTION

Always use an open-end spanner 22 mm or similar

on the mounting flange, when tightening.

Attachment screws

Attachments Note
Suitable screws, lightly lubricated: M4 (Length depending on tool)
Suitable washer.
Tightening torque. See section Screw joints on page 155.

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2.4.8 Loads

2.4.8 Loads

General
This section describes loads from external equipment. For information about
general loads and diagrams see Product specification - IRB 360.

Extra equipment attached to the manipulator arms

xx0700000716

M1 Limitation lines for center of gravity for M1

M2 Limitation lines for center of gravity for M2

The robot is tuned for handling the weight of a vacuum system or a medium sized
hose. Other equipment attached to M1 and/or M2 should be calculated as a point
load located in the same position as TCPO. This point load needs to be added to
the calculation of the users normal tool load and declared in used tooldata, see
Extra load mass to be calculated on page 72.

Extra load mass to be calculated

Part on arm Weight Action

system
M1 0-175 g Allowed. Do not calculate the extra load mass.
175 g - 350 g Calculate the extra load mass by subtracting the weight
with 175 g. i
350 g and above Not allowed.
Continues on next page
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2.4.8 Loads
Continued

Part on arm Weight Action

system
M2 0-175 g Allowed. Do not calculate the extra load mass.
175 g - 350 g Calculate the extra load mass by subtracting the weight
with 175 g. i
350 g and above Not allowed.
i Combine the extra load mass weight of M1 and M2 together and add the weight as a point mass
in the center of the customer interface (TCP 0). This addition can be done in the tool definition or
the payload definition. If only one of M1 or M2 needs to be calculated, add only that extra load mass
subtracted with 175g in TCP 0.

Example of calculating the extra load mass

If the extra equipment (excluding option equipments) attached to M1 has the load
mass of 210 g and the extra equipment attached on M2 has the load mass of 240
g, then the calculated extra load mass for M1 is (210 g - 175 g = 35 g) and for M2
(240 g - 175 g = 65 g). Adding together the calculated load mass for M1 and M2
(35 g + 65 g = 100 g) gives the correct amount of 100 g located at the same position
as TCP0. This point load needs to be added to the calculation of the users tool
load and declared in used tooldata.

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2.5.1 Installation of safety lamp (option 213-1)

2.5 Installation of options

2.5.1 Installation of safety lamp (option 213-1)

General
This section describes installation of safety lamp.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Location

xx0700000546

A Warning lamp.
B Screw M8 of suitable length.

Continues on next page

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2.5.1 Installation of safety lamp (option 213-1)
Continued

Required equipment and references

Equipment Spare Part No. Note

Standard tools. Standard toolkit on page 258
Safety lamp (option). Spare parts - customer op-
tions signal lamp IRB 360.
Cover 3HAC028966-006
Cover gasket 3HAC028972-001

References
Replacement of base cover gasket on page 160
Standard toolkit on page 258

Installation

xx0700000577

A Safety lamp connectors R3.H1and R3.H2

B Lead-through in cover plate for the optional safety lamp.
C Cover gasket 3HAC028972-001
D 4pcs Screw M6x20
F FB7 connector for resolver signals for axis 7 (Option 864-1)

Continues on next page

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2.5.1 Installation of safety lamp (option 213-1)
Continued

Action Note
1 Remove the base cover Described in section Replacement
of base cover gasket on page 160
2 Replace the cover plate with the optional safety Tightening torque 4 Nm
lamp cover plate with gasket.
3 Locate the connectors R3.H1 - R3.H2 and connect
the safety lamp harness to it.
4 Mount the safety lamp. Placement is optional.

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2.5.2 Installation of (optional) customer connections IRB 360

2.5.2 Installation of (optional) customer connections IRB 360

General
This section describes installation of customer connections.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Continues on next page

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2.5.2 Installation of (optional) customer connections IRB 360
Continued

Location

en0700000642

Connections in customer cable

Wire Spec. Connection point A Connection point B Note

Desig- Term Type Desig- Term Type
nation nation
Power
1 RD XP5 A1 2 R1.CP 1 13
2 BU XP5 B1 2 R1.CP 2 13
3 GN XP5 C1 2 R1.CP 3 13

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2.5.2 Installation of (optional) customer connections IRB 360
Continued

Wire Spec. Connection point A Connection point B Note

Desig- Term Type Desig- Term Type
nation nation
4 YE XP5 D1 2 R1.CP 4 13
5 WH XP5 A2 2 R1.CP 5 13
6 BK XP5 B2 2 R1.CP 6 13
7 BN XP5 C2 2 R1.CP 8 13
8 VT XP5 D2 2 R1.CP 9 13
9 OG XP5 A3 2 R1.CP 10 13
10 PK XP5 B3 2 R1.CP 11 13
11 TQ Conductor to cut off.
12 GY XP5 Earth 19 R1.CP 12 13 i

SHIELD XP5 Earth 20 Earth 0V (ground) ii

Ref. (shield)
(DP
shield)

Signals
Pair
1.1 1 WH XP5 B5 4 R1.CS 1 15
1.2 1 BU XP5 C5 4 R1.CS 2 15
2.1 2 WH XP5 D5 4 R1.CS 3 15
2.2 2 OG XP5 A6 4 R1.CS 4 15
3.1 3 WH XP5 B6 4 R1.CS 5 15
3.2 3 GN XP5 C6 4 R1.CS 6 15
4.1 4 WH XP5 D6 4 R1.CS 7 15
4.2 4 BN XP5 A7 4 R1.CS 8 15
5.1 5 WH XP5 B7 4 R1.CS 9 15
5.2 5 GY XP5 C7 4 R1.CS 10 15
6.1 6 RD XP5 D7 4 R1.CS 11 15
6.2 6 BU XP5 A8 4 R1.CS 12 15
7.1 7 RD XP5 B8 4 R1.CS 13 15
7.2 7 OG XP5 C8 4 R1.CS 14 15
8.1 8 RD XP5 D8 4 R1.CS 15 15
8.2 8 GN XP5 A9 4 R1.CS 16 15
9.1 9 RD XP5 B9 4 R1.CS 17 15
9.2 9 BN XP5 C9 4 R1.CS 18 15
10.1 10 RD XP5 D9 4 R1.CS 19 15
10.2 10 GY XP5 A10 4 R1.CS 20 15
11.1 11 BK XP5 B10 4 R1.CS 21 15
11.2 11 BU XP5 C10 4 R1.CS 22 15

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2.5.2 Installation of (optional) customer connections IRB 360
Continued

Wire Spec. Connection point A Connection point B Note

Desig- Term Type Desig- Term Type
nation nation
12.1 12 BK XP5 D10 4 R1.CS 23 15
12.2 12 OG Conductor to cut off.
13.1 13 BK Conductor to cut off.
13.2 13 GN Conductor to cut off.
14.1 Conductor to cut off.
14.2 Conductor to cut off.
15.1 Conductor to cut off.
15.2 Conductor to cut off.
16.1 Conductor to cut off.
16.2 Conductor to cut off.
Shield XP5 Earth 20 0V (Ground) ii
Ref.
(DP
shield)
i Use green/yellow shrinking hose on free conductors, in both ends.
ii Dual press both shields, and connect them to earth.

Installation

Action Note
1 Remove the standard cover plate.
2 Fit the self-adhesive gasket on the customer cover
plate.
3 Install the customer cable harness. Use standard tools.
4 Assemble the customer cover plate using the four Tightening torque 4 Nm
attachment screws.

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2.5.3 Installation of vacuum system (option 218-9)

2.5.3 Installation of vacuum system (option 218-9)

General
This section describes installation of (optional) vacuum system on an IRB 360.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Continues on next page

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2.5.3 Installation of vacuum system (option 218-9)
Continued

Locations

xx0700000654

A Ejector unit
B R1.CS
C Exhaust air
D Vacuum In
E Compressed air in (max. 6 bar)
F Vacuum switch
G Air filter (compressed air side)
H Air filter (vacuum side)

Continues on next page

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2.5.3 Installation of vacuum system (option 218-9)
Continued

Mechanical installation ejector

xx0700000714

A Attachment
B Bracket
C Hexagon head screw, M8x35 (Steel 8.8-A2F)
D Ejector unit
E Hexagon bolt with flange, M6 x 20 (A2 DIN6921)
F Gasket

Action Note
1 Follow the refitting instructions in section Replace-
ment of ejector unit on page 216

Continues on next page

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2.5.3 Installation of vacuum system (option 218-9)
Continued

Installation of hoses

xx0700000710

Action Note
1 Follow the refitting instructions in section Replace-
ment of vacuum hoses on page 211.

Electrical installation
When connecting to IRC5 controller

Action Note
1 Assemble the customer cable 3HAC14860-X. X = Depending on length, see
section Robot cabling and connec-
tion points on page 86
2 Use connection R1.CS on the front of the ejector
unit, and the other end to the XP5 socket on the
controller.

When connecting to OmniCore controller

Action Note
1 Assemble the customer cable 3HAC14860-X. X = Depending on length, see
section Robot cabling and connec-
tion points on page 86

Continues on next page

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2.5.3 Installation of vacuum system (option 218-9)
Continued

Action Note
2 Use connection R1.CS on the front of the ejector
unit.
3 Cut open the XP5 connector into several open ends.
4 Assemble the open ends to the local I/O on the
controller.

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2 Installation and commissioning
2.6.1 Robot cabling and connection points

2.6 Electrical connections

2.6.1 Robot cabling and connection points

General
Connect the robot and controller to each other after securing them to the foundation.
The following lists specify which cables to use for each respective application.

Cable categories

Cable category Description

Robot power cables Handles power supply to the robot's motors.
Robot signal cables Handles signals from the controller to the robot's motors, as
well as feedback from the serial measurement board.
Customer cables (option) Handles communication with equipment fitted on the robot by
the customer, low voltage signals and high voltage power
supply + protective ground.

Robot control cable

These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable (power) Transfers drive power from XS1 (IRC5) R1.MP1-3
the drive units in the control XP1 (OmniCore) R1.MP4-6
cabinet to the robot motors.
Robot cable, (signals) Transfers resolver data from S (IRC5) X1(SMB)
and power supply to the seri- XP2 (OmniCore)
al measurement board.

Robot control cable (power and signal) for IRC5

These cables are sold in pair, including both one robot cable power, and one robot
cable signal.
Cable Art. no.
Robot control cable 3 m 3HAC029903-001
Robot control cable 7 m 3HAC029903-002
Robot control cable 15 m 3HAC029903-003
Robot control cable 22 m 3HAC029903-004
Robot control cable 30 m 3HAC029903-005

Robot control cable (power and signal) for Panel Mounted Controller
These cables are included in the standard delivery for the Panel Mounted Controller.
The cable needs to be cut off and prepared to fit the controller's connection points,
as described in the product manual for the controller.
Cable Art. no.
Robot control cable 7 m 3HAC029903-002

Continues on next page

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 2 Installation and commissioning
2.6.1 Robot cabling and connection points
Continued

Robot control cable (power and signal) for OmniCore

These cables are sold in pair, including both one robot cable power, and one robot
cable signal.
Cable Art. no.
Robot control cable 3 m 3HAC062959-003
Robot control cable 7 m 3HAC062959-004
Robot control cable 15 m 3HAC062959-005
Robot control cable 22 m 3HAC062959-006
Robot control cable 30 m 3HAC062959-007

Customer connections
Customer connection (optional)
These cables including both power and signals are optional and can not be
combined with customer vacuum connections.
Cable Art. no.
Customer control cable 3 m 3HAC030198-001
Customer control cable 7 m 3HAC030198-002
Customer control cable 15 m 3HAC030198-003
Customer control cable 22 m 3HAC030198-004
Customer control cable 30 m 3HAC030198-005

Customer vacuum connection (optional)

Signal cables for vacuum are optional and can not be combined with customer
connections.
Cable Art. no.
Customer control cable 3 m 3HAC14860-7
Customer control cable 7 m 3HAC14860-1
Customer control cable 15 m 3HAC14860-2
Customer control cable 22 m 3HAC14860-3
Customer control cable 30 m 3HAC14860-4

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2 Installation and commissioning
2.7 Start of robot in cold environments

2.7 Start of robot in cold environments

Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.

Problems with starting the robot

Event message from Motion Supervision
Use this procedure if an event message indicates a problem with Motion supervision
at start-up. More information about Motion Supervision is found in Technical
reference manual - System parameters.
Action Note
1 Turn off Motion Supervision.
2 Start the robot.
3 When the robot has reached normal working temper-
ature, the Motion Supervision can be turned on
again.

Robot stopping with other event message

Use this procedure if the robot is not starting.
Action Note
1 Start the robot with its normal program but The speed can be regulated with the
with reduced speed. RAPID instruction VelSet.

Adjusting the speed and acceleration during warm-up

Depending on how cold the environment is and what program is being used, the
speed might need to be ramped up until reached maximum. The table shows
examples of how to adjust the speed:
Work cycles AccSet Speed/velocity
3 Work cycles 20, 20 v100 (100 mm/s)
5 Work cycles 40, 40 v400 (400 mm/s)
5 Work cycles 60, 60 v600 (600 mm/s)
5 Work cycles 100, 100 v1000 (1000 mm/s)
More than 5 Work cycles 100, 100 Max.

If the program consists of large wrist movements, it is possible that the reorientation
velocity, which is always high in predefined velocities, needs to be included in the
ramping up.

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 3 Maintenance
3.1 Introduction

3 Maintenance
3.1 Introduction

Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB
360.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided according to the
maintenance activity.

Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any service
work.

Note

If the IRB 360 is connected to power, always make sure that the IRB 360 is
connected to protective earth and a residual current device (RCD) before starting
any maintenance work.
For more information see:
• Product manual - OmniCore C30
• Product manual - IRC5
• Product manual - IRC5 Compact
• Product manual - IRC5 Panel Mounted Controller
• Robot cabling and connection points on page 86.

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3 Maintenance
3.2.1 Specification of maintenance intervals

3.2 Maintenance schedule

3.2.1 Specification of maintenance intervals

Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the IRB 360:
• Calendar time: specified in months regardless of whether the system is
running or not.
• Operating time: specified in operating hours. More frequent running means
more frequent maintenance activities.
• SIS: specified by the robot's SIS (Service Information System). A typical
value is given for a typical work cycle, but the value will differ depending on
how hard each part is run.
The SIS used in M2004 is further described in the Operating manual - Service
Information System.
The SIS used in OmniCore is further described in the Operating manual - IRC5
with FlexPendant.
Robots with the functionality Service Information System activated can show active
counters in the device browser in RobotStudio, or on the FlexPendant.

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 3 Maintenance
3.2.2 Regular maintenance

3.2.2 Regular maintenance

Recommendation
The robot is designed to be able to work under very demanding conditions with a
minimum of maintenance. Time between services can vary depending on the
influence of the environment the robot is exposed for. We strongly recommend
that at every stop in production, especially after collisions and after every wash
down, the robot is inspected concerning the following parts.

Inspect regularly
• Telescopic shaft
• Spring units
• Bars
• Universal joints

Preventive maintenance
Nevertheless, certain routine checks and preventive maintenance must be carried
out at specified periodic intervals, as shown in the following table.
Preventive maintenance Note
Clean the robot. As described in section Clean-
ing activities on page 136.
Lubricate sealings: Recommended lubrication, see
• At regular intervals section:
• When needed. • Mounting instructions for
bearings on page 150

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3 Maintenance
3.2.3 Maintenance schedule IRB 360

3.2.3 Maintenance schedule IRB 360

Maintenance schedule

Maintenance Equipment Daily 400h 500h 4,000h 30,000h

activity 2 year 5 year
Inspection Clean Room robot xi
Inspection Telescopic shaft x
Inspection Vacuum system x ii x
Inspection Bar system x x
Inspection Upper arms x
Inspection Spring unit x iii
Inspection Movable plate x
Inspection Sealing ring (V-ring) xi
Inspection Information labels
Grease Telescopic shaft (WDS) x iv
Grease Bearing rings 3HAC2091-1 v x
Changing Telescopic shaft including x
universal joints
Changing Gearboxes oil, axes 1, 2, and x vi
3
Changing Gearbox oil, axis 4 x vi
Replacement Battery pack, measurement 36 months
system of type RMU101 or or battery
RMU102 (3-pole battery con- low alert
tact) vii

Replacement Battery pack, measurement 24 months

system with 2-pole battery or battery
contact, e.g. DSQC633A low alert
viii

i Check for abnormal wear or contamination.

ii Only if option is chosen. Change interval is dependant on the material in picked objects. Porous
objects may cause shorter cleaning intervals.
iii Grease if the spring units make a grinding sound.
iv Check for abnormal wear or contamination
v There are two different types of bearing rings, 3HAC028087-001 is maintenance-free, 3HAC2091-1
must be lubricated according to maintenance schedule. See Different versions of bearing rings
require different maintenance procedures on page 104.
vi Oil should only be changed once after the first 30,000 h.
vii The battery low alert (38213 Battery charge low) is displayed when the battery needs to be replaced.
The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned
on until the battery is to be replaced.
See the replacement instruction for more details.
viii The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the
robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime
can be extended with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.

Continues on next page

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 3 Maintenance
3.2.3 Maintenance schedule IRB 360
Continued

Check regularly
Check regularly:
• Wear of bearing ring in joints of the arm system.
• For any oil leaks. If a major oil leak is discovered, call for service personnel.
• For excessive play in gears. If play develops, call for service personnel.
• That the cabling between the control cabinet and robot is not damaged.
• Wear of plain bearings in telescopic shaft (wash-down protection).

Cleaning
Cleaning:
• Clean the robot exterior with a cloth when necessary. Do not use aggressive
solvents which may damage paint or cabling. See section Cleaning activities
on page 136.
• Cleaning instructions for wash down version, see section Cleaning activities
on page 136.

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3 Maintenance
3.3.1 Telescopic shaft, axis 4, standard

3.3 Inspection activities

3.3.1 Telescopic shaft, axis 4, standard

General
This section describes maintenance on the telescopic shaft, axis 4, with the interval
500 hours.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Note

The wear on the bearings depends on the payload, cycle, environment, and
lubrication.

Telescopic shaft

xx0700000556

A Telescopic shaft (STD)

B Universal joint
C Set screw, dog point

Continues on next page

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 3 Maintenance
3.3.1 Telescopic shaft, axis 4, standard
Continued

Required equipment and references

Required equipment Note

Standard tools Standard toolkit on page 258.

References
Replacement of telescopic shaft on page 182
Spare parts, telescopic shaft.

Interval 500 h

Action Note
1 Check and retighten the set screws in the universal Described in section Replacement
joints. of telescopic shaft on page 182.

Interval 4000 h

Action Note
1 Change the telescopic shaft and the universal joint. Spare parts, telescopic shaft

After a collision and/or if arms have fallen off

Action Note
1 Remove any remaining parts of the bar system from
the movable plate. CAUTION

Be careful when pulling out the

telescope to full length.

2 Check for damages on the universal joint. How to replace the universal joint,
see section:
• Replacement of universal
joint on page 185
3 Move the movable plate in different directions in How to replace the universal joint,
order to check if there are any indications of re- see section:
duced moving ability of the universal joint. • Replacement of universal
joint on page 185

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3 Maintenance
3.3.2 Telescopic shaft, wash down, axis 4

3.3.2 Telescopic shaft, wash down, axis 4

General
This section describes maintenance on the telescopic shaft (wash down), axis 4
interval 500 and 4000 h

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Note

The wear on the bearings depends on the payload, cycle, environment, and
lubrication.

Telescopic shaft

xx0700000717

Required equipment and references

References
Replacement of telescopic shaft on page 182
Spare parts, telescopic shaft.

Continues on next page

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 3 Maintenance
3.3.2 Telescopic shaft, wash down, axis 4
Continued

Interval 500 h

Action Note
1 Check and retighten set screws.
2 If the linear bushings are worn out or if the backlash Described in section Replacement
is excessive, change the telescopic shaft and the of telescopic shaft on page 182.
universal joint.

Interval 4000 h

Action Note
1 Change the telescopic shaft and the universal joint. Spare parts, telescopic shaft

After a collision and/or if arms have fallen off

Action Note
1 Remove any remaining parts of the bar system from
the movable plate. CAUTION

Be careful when pulling out the

telescope to full length.

2 Check for damages on the universal joint. How to replace the universal joint,
see section:
• Replacement of universal
joint on page 185
3 Move the movable plate in different directions in How to replace the universal joint,
order to check if there are any indications of re- see section:
duced moving ability of the universal joint. • Replacement of universal
joint on page 185

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3 Maintenance
3.3.3 Telescopic shaft, stainless, axis 4

3.3.3 Telescopic shaft, stainless, axis 4

General
This section describes maintenance on the telescopic shaft (stainless), axis 4
interval 500 and 4000 h

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Note

The wear on the bearings depends on the payload, cycle, environment, and
lubrication.

Note

The stainless version is not available for the IRB 360 used with OmniCore
controllers.

Continues on next page

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 3 Maintenance
3.3.3 Telescopic shaft, stainless, axis 4
Continued

Telescopic shaft

xx0700000498

A Telescopic shaft (WDS)

B Universal joint
C Set screw, dog point
D Grease nipple (ball-type, DIN 3402)

Required equipment and references

Required equipment Spare part No. Note

Grease gun For ball-type nipples
(DIN 3402)
Grease Grease specification on page 261.
Telescopic shaft Spare parts, telescopic shaft
Standard tools Standard toolkit on page 258.

References
Spare parts, telescopic shaft
Replacement of telescopic shaft on page 182

Continues on next page

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3 Maintenance
3.3.3 Telescopic shaft, stainless, axis 4
Continued

Interval 500 h

Action Note
1 Check and retighten the set screws in the universal
joints.
2 Lubricate the linear bushing, using a shot lubricator.
3 If the linear bushing are worn out or if the backlash Described in section Replacement
is excessive, replace the telescopic shaft. of telescopic shaft on page 182

Interval 4000 h

Action Note
1 Change the telescopic shaft and the universal joints. Spare parts, telescopic shaft

After a collision and/or if arms have fallen off

Action Note
1 Remove any remaining parts of the bar system from
the movable plate. CAUTION

Be careful when pulling out the

telescope to full length.

2 Check for damages on the universal joint. How to replace the universal joint,
see section:
• Replacement of universal
joint on page 185
3 Move the movable plate in different directions in How to replace the universal joint,
order to check if there are any indications of re- see section
duced moving ability of the universal joint. • Replacement of universal
joint on page 185

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 3 Maintenance
3.3.4 Vacuum system (optional)

3.3.4 Vacuum system (optional)

General
This section describes maintenance on the vacuum system, with the intervals 500
and 4000 hours.

Note

Only use in lubricated air.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Continues on next page

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3 Maintenance
3.3.4 Vacuum system (optional)
Continued

Vacuum system

xx0700000499

A Air filter inlet

B Ejector unit
C Air filter inlet vacuum
D Swivel cup
E Hose clamp

Required equipment and references

Required equipment Spare part no. Note

Pneumatic valve unit Spare parts, ejector unit.

References
Replacement of ejector unit on page 216
Draining of water separation filter on page 214

Continues on next page

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 3 Maintenance
3.3.4 Vacuum system (optional)
Continued

Interval 500 h

Action Note
1 Empty air filter and check the position of the Described in section Draining of water
clamps for the hose. separation filter on page 214.
2 Correct the positions on the outer clamps. Positions shown in figure.
3 Check that the air supply is dry and clean. Particle size must not exceed 5 µm

Interval 4,000 h or 2 Years

Action Note
1 Replace pneumatic valves. The service life of the valves is
4x10 7 cycles.
Described in section Replacement
of ejector unit on page 216

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3 Maintenance
3.3.5 Bar system

3.3.5 Bar system

General
This section describes maintenance on the bar system, with the intervals 500 and
4000 hours.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Note

The wear on the bearing rings depends on the payload, number of cycles, and
environment. Collisions can damage the bearing rings!

CAUTION

The spring units must be removed according to the description in section

Replacement of parallel arms on page 167or they will be damaged.

Note

Never use grease on the bar system.

Different versions of bearing rings require different maintenance procedures

Valid for robot versions: IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB
360 - 1/1600.
At delivery the robot is equipped with bearing rings 3HAC028087-001. These are
maintenance free.
In specific environments the bearing rings 3HAC028087-001 might have been
changed to bearing rings 3HAC2091-1 after delivery. These must be lubricated
regularly.
The bearing rings 3HAC028087-001 are white. The bearing rings 3HAC2091-1 are
grey.

Required equipment and references

Required equipment Spare part no. Note

Bearing rings For article number see:
• Spare parts - parallel arm
system, IRB 360.

Continues on next page

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 3 Maintenance
3.3.5 Bar system
Continued

Required equipment Spare part no. Note

Grease - Required for non-maintenance
free bearing rings.
• Mobilgrease FM 102
• Optimol Obeen UF 2
See Different versions of bearing
rings require different mainten-
ance procedures on page 104.

References
Replacement of bearing rings on page 175

After a collision and/or if arms have fallen off

Action Note
1 Check for damages on bearing rings. If How to change bearing rings, see section:
needed, replace. • Replacement of bearing rings on
page 175
2 Check for contamination and/or residues of If needed clean the bearing rings with
grease. ethanol.
3 Lubricate bearing rings that are not mainten- Type of grease, see Required equipment
ance-free (see Different versions of bearing and references on page 104.
rings require different maintenance proced-
ures on page 104).

Maintenance activity with interval 500 hours or 1 year

Action Note
1 Check for wear on bearing rings, listen for How to replace bearing rings, see section:
screeching. • Replacement of bearing rings on
Replace if needed. page 175

2 Lubricate bearing rings that are not mainten- Type of grease, see Required equipment
ance free (see Different versions of bearing and references on page 104.
rings require different maintenance proced-
ures on page 104).

Maintenance activity with interval 4,000 hours or 2 years

Action Note
1 Check surface of tube for cracks or damages. Replace if damaged.
2 Check the distance between the bearing holders. See Distance between bearing
holders on page 106.
3 If needed, replace damaged parts as described in
the repair chapter.

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3 Maintenance
3.3.5 Bar system
Continued

Bar system wear

xx0700000484

A Wear on bearing rings

B Wear on spring unit forks

Distance between bearing holders

Note

The bearing will normally wear a lot during the first hours of operation (0.1-0.5
mm). It may also show wear in the form of dust and small particles. After this
initial run-in, wear will reduce significantly.

Action Note
1 Measure the distance A between the bearing IRB 360 Std:
holders, according to the figure. A
Refer to the table below to see what distance re-
quires replacement of the bearing ring.
Replace the bearing ring, if required, according
to section Replacement of bearing rings on
page 175.

xx1000000018

IRB 360 WDS:

A

xx2000002385

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 3 Maintenance
3.3.5 Bar system
Continued

Robot variant Distance A

Initial value Value that requires replace- Worn out value i
ment of the bearing ring
IRB 360 - 1/1130 126 mm (Std) <125 mm (Std) 124 mm (Std)
IRB 360 - 3/1130 130 mm (WDS) <129 mm (WDS) 128 mm (WDS)
IRB 360 - 1/800
IRB 360 - 1/1600
IRB 360 - 8/1130 130 mm <129 mm 128 mm
IRB 360 - 6/1600
i The bearing ring is worn out and requires immediate replacement. Operating the robot beyond this
value will cause permanent damage to the arm system components.

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3 Maintenance
3.3.6 Joint balls

3.3.6 Joint balls

General
This section describes maintenance on the joint balls, with the interval 4000 hours.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Check joint balls

xx0700000500

A Movable plate
B Joint balls

Required equipment and references

Required equipment Spare part No. Note

Standard tools Standard toolkit on page 258
Pliers for parallel arms 3HAC6194-1

References
Replacement of joint balls on page 187

Interval 4,000 hours or 2 years

Action Note
1 Check surface of joint balls for cracks or burrs. If necessary replace the part as de-
scribed in Replacement of joint balls
on page 187

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 3 Maintenance
3.3.7 Upper arms

3.3.7 Upper arms

General
This section describes maintenance on the upper arms, with the interval 4000
hours.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Check upper arm

xx0700000501

A Upper arm tube

B Joint balls

Continues on next page

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3 Maintenance
3.3.7 Upper arms
Continued

Required equipment and references

Required equipment Spare part no. Note

Standard tools Standard toolkit on page 258

References
Replacement of joint balls on page 187
Replacement of upper arm on page 172

Interval 4,000 hours or 2 years

Action Note
1 Check the surface of the tube for cracks. If necessary replace the part as
described in section Replacement
of upper arm on page 172
2 Check surface of joint balls for cracks or burrs. If necessary replace the part as
described in Replacement of joint
balls on page 187

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 3 Maintenance
3.3.8 Hoses

3.3.8 Hoses

General
This section describes maintenance on the hoses with the interval 500 hours.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Check hoses

xx0700000499

A Air filter inlet.

B Ejector unit
C Air filter inlet vacuum.
D Swivel cup
E Hose clamp

Continues on next page

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3 Maintenance
3.3.8 Hoses
Continued

Required equipment and references

Required equipment Spare part no. Note

Standard tools Standard toolkit on page 258

References
Replacement of vacuum hoses on page 211

Interval 500 hours

Action Note
1 Check the entire hose and make sure there are no If necessary, exchange the part
folds or surface damage. as described in Replacement of
vacuum hoses on page 211

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 3 Maintenance
3.3.9 Spring units

3.3.9 Spring units

General
This section describes maintenance on the spring units with the interval 500 hours.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

CAUTION

The spring units must be removed according to the description in section

Replacement of parallel arms on page 167or they will be damaged.

Check spring units

IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600

xx0700000497

A Hook
B Spring
C Rubber bellow
G Greasing points

Continues on next page

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3 Maintenance
3.3.9 Spring units
Continued

IRB 360 - 8/1130, IRB 360 - 6/1600

xx1300000162

A Hook
B Spring
G Greasing points

Required equipment and references

Required equipment Spare part no. Note

Grease Grease specification on
page 261
Standard tools Standard toolkit on page 258
Spring Spare parts - lower arm sys-
tem, IRB 360.

References
Replacement of parallel arms on page 167

Interval 500 hours

Action Note
1 Check the forks for wear. If necessary exchange the part as
described in Replacement of par-
allel arms on page 167
2 If necessary (if the spring units make a grinding Shown in figure as (G)
sound) apply grease to all wear surfaces.

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 3 Maintenance
3.3.10 Movable plate

3.3.10 Movable plate

General
This section describes maintenance on the movable plate, with the interval 4,000
hours.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Check movable plate

xx0700000502

A Tool interface axis 4

Required equipment and references

Required equipment Spare part no. Note

Movable plate Spare parts, movable plate.
Standard tools Standard toolkit on page 258.

Continues on next page

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3 Maintenance
3.3.10 Movable plate
Continued

References
Replacement of movable plate on page 178

Interval 4000 hours

CAUTION

Never force axial movement to the swivel or tool interface without first releasing
the brakes, it will damage the telescopic shaft.

Action Note
1 Release the holding brakes on the As described in section Manually releasing the
robot axis 4. brakes on page 64.
2 Check axis 4 so that the rotation is If necessary replace the movable plate as de-
smooth. scribed in Replacement of movable plate on
page 178

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 3 Maintenance
3.3.11 Inspecting information labels

3.3.11 Inspecting information labels

Location of information labels

The figure shows the location of the information labels to be inspected.
A
H H
H
(Axis 1) (Axis 2)

(Axis 1)
x x J

F
Axis 2 K
E B E
z
D D

K Axis 1

G
K
D
z Axis 3 C SECTION z-z
SECTION x-x

xx1800001185

A ABB logotype
B Calibration label
C Warning label - Brake release
D Warning label - Electricity (symbol of flash) (3 pcs)
E Rating label (2 pcs)
F UL/UR label
G Instruction label
Before dismantling see product manual
J Label, FlexPicker
K Axis marking

Required equipment

Equipment Spare part number Note

Labels See Spare part lists on
page 267.

Continues on next page

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3 Maintenance
3.3.11 Inspecting information labels
Continued

Inspecting labels
Use this procedure to inspect the labels on the robot.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

2 Check all labels. See the figure in Location of information

labels on page 117.
3 Replace any missing or damaged labels.

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 3 Maintenance
3.4.1 Changing the battery in the measuring system

3.4 Replacement/changing activities

3.4.1 Changing the battery in the measuring system

Note

The battery low alert (38213 Battery charge low) is displayed when the battery
needs to be replaced. The recommendation to avoid an unsynchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For an SMB board with 2-pole battery contact, the typical lifetime of a new battery
is 36 months if the robot is powered off 2 days/week or 18 months if the robot is
powered off 16 h/day. The lifetime can be extended for longer production breaks
with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

CAUTION

Always read the specific instructions for Clean Room robots before doing any
repair work, see Cut the paint or surface on the robot before replacing parts on
page 158.

Continues on next page

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3 Maintenance
3.4.1 Changing the battery in the measuring system
Continued

Location SMB
DSQC 633A

xx0700000506

A SMB battery

Continues on next page

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 3 Maintenance
3.4.1 Changing the battery in the measuring system
Continued

RMU 101

xx1300000353

Required equipment and references

Note

There are two variants of SMB units and batteries. One with 2-pole battery contact
and one with 3-pole battery contact. The variant with the 3-pole battery contact
has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!

Tools and wear parts Spare part no. Note

Battery unit See Product manual, spare Lithium battery
parts - IRB 360.
Standard tools Standard toolkit on page 258
Battery retainer (strap)

References
Updating revolution counters on page 241
Replacement of base cover gasket on page 160

Continues on next page

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3 Maintenance
3.4.1 Changing the battery in the measuring system
Continued

Changing the battery

DANGER

Turn off all electric power, hydraulic, and pneumatic pressure supplies to the
robot.

Action Note
1 Remove the (12pcs) M6 screws hold- Described in section Replacement of base
ing the base cover. cover gasket on page 160.
2 Remove the base cover.

CAUTION

Clean cover from metal residues be-

fore opening.
Metal residues can cause shortage
on the boards which can result in
hazardous failures.

CAUTION

Always cut the paint with a knife and

grind the paint edge when disas-
sembling parts. See Cut the paint or
surface on the robot before replacing
parts on page 158.

3 Disconnect the battery from the serial

measurement board.
Connection (X3).
4 Cut the strap and remove the battery
pack. Note
Use standard tools.
Used batteries must never be thrown away!
They must be handled as hazardous waste!

5 Connect the new battery to the serial

measurement board.
Connection (X3).
6 Refit the battery to the SMB, using a
strap.
7 Check the base cover gasket. Replace if damaged.
8 Refit the base cover using the (12pcs) Described in section Replacement of base
M6 screws. cover gasket on page 160.
9 Update the revolution counters. Described in section Updating revolution
counters on page 241.

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 3 Maintenance
3.4.2 Changing the telescopic shaft including universal joints

3.4.2 Changing the telescopic shaft including universal joints

General
This section describes maintenance on the telescopic shaft with the interval 4000
hours or 2 years.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Note

The wear on the bearings depends on the payload, cycle, environment, and
lubrication.

Telescopic shaft

xx0700000556

A Telescopic shaft (STD)

B Universal joint
C Set screw, dog point

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3 Maintenance
3.4.2 Changing the telescopic shaft including universal joints
Continued

Required equipment and references

Required equipment Note

Standard tools Standard toolkit on page 258.

References
Replacement of telescopic shaft on page 182
Spare parts, telescopic shaft.

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Interval 4,000 h or 2 Years

Action Note
1 Change the telescopic shaft and the universal joints. Described in section Replacement
of telescopic shaft on page 182.

After a collision and/or if arms have fallen off

See After a collision and/or if arms have fallen off on page 95.

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 3 Maintenance
3.5.1 Type of lubrication in gearboxes

3.5 Lubrication activities

3.5.1 Type of lubrication in gearboxes

Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with lubrication.

Type and amount of oil in gearboxes

Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes available for registered users on myABB Business Portal,
www.abb.com/myABB.

Location of gearboxes
The figure shows the location of the gearboxes.

xx1300000177

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3 Maintenance
3.5.1 Type of lubrication in gearboxes
Continued

xx1300000178

A Axis-1 gearbox
B Axis-2 gearbox
C Axis-3 gearbox
D Axis-4 gearbox

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 3 Maintenance
3.5.2 Gearboxes, axes 1- 4

3.5.2 Gearboxes, axes 1- 4

General
This section describes maintenance on axis-1-4 gearboxes regarding oil change
(3D version only 1-3).

WARNING

Gearbox oil can be very hot, take necessary measures to collect the oil.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

CAUTION

Always read the specific instructions for Clean Room robots before doing any
repair work, see Cut the paint or surface on the robot before replacing parts on
page 158.

Continues on next page

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3 Maintenance
3.5.2 Gearboxes, axes 1- 4
Continued

Location of gearboxes

xx0700000505

A Gearbox axis 1
B Gearbox axis 2
C Gearbox axis 3
D Gearbox axis 4 (not in 3D version)

Required equipment and references

Required equipment Spare part No. Note

Standard tools Standard toolkit on page 258
Gaskets base Spare parts, gaskets in the base
Gaskets cover Spare parts, transmission cover
Spare parts, gear units axis 1- 3 Spare parts, gear units axis 1- 3
Spare parts, gear units axis 4 Spare parts, gear unit axis 4
Locking liquid Loctite 243
Sealing compound 3HAC073510-001 Trans7

Continues on next page

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 3 Maintenance
3.5.2 Gearboxes, axes 1- 4
Continued

References
Replacement of base cover gasket on page 160
Replacement of parallel arms on page 167
Replacement of telescopic shaft on page 182
Replacement of upper arm on page 172

Interval 30,000 hours or 5 years

Oil change in axis 4, (not in 3D version)

Note

Oil should only be changed once after the first 30,000 h.

Action Note
1 Remove the base cover. Described in section Replacement of base cover gasket on
page 160.
2 Remove the gearbox Described in section Replacement of gearbox unit 4 on
and motor axis 4. page 194.
3 Remove the oil plug,
and drain the oil from
gearbox 4.

xx0700000728

4 Fill new oil through the Types and volumes of oil are specified in the Technical refer-
plug holes, with spe- ence manual - Lubrication in gearboxes - 3HAC042927-001.
cified volume.

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3 Maintenance
3.5.2 Gearboxes, axes 1- 4
Continued

Action Note
5 Refit the oil plug, apply Tightening torque: 3 Nm .
Loctite 243.

Note

If the sealing ring on the

sealing plug is dam-
aged, change the seal-
ing plug.

Note

Some robots have two

oil plugs.

6 Refit the (12 pcs) M6 Described in section Replacement of base cover gasket on
screws holding the base page 160.
cover.
(If necessary, change
the sealings)

Interval 30,000 hours or 5 years

Oil change in axis 1-3
Action Note
1 Remove the (12 pcs) Described in section Replacement of base cover gasket on
M6 screws holding the page 160.
base cover.
2 Remove the parallel Described in section Replacement of parallel arms on page 167.
arms.
3 Remove the telescopic Described in section Replacement of telescopic shaft on
shaft page 182.
4 Remove the 3 pcs VK- Use a screwdriver
covers.
5 Remove the 3x6 pcs Described in section Replacement of upper arm on page 172.
M6x40 holding the up-
per arms.
6 Remove the 6 pcs
M6x20 (A) holding the
3 pcs flange (B) and the
3 pcs upper arm sealing
rings.

xx0700000509

A Screw M6x20
B Flange

Continues on next page

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 3 Maintenance
3.5.2 Gearboxes, axes 1- 4
Continued

Action Note
7 Remove the 3 pcs
M6x20 flange screws
(A).
Remove the flange cov-
er (B).
Remove the flange
gasket ax 4 (C).
Remove the sealing
ring (D).

xx0700000647

A M6x20 flange screws.

B Flange cover ax 4 (in 3D version without center hole)
C Flange gasket ax 4
D Sealing ring w. dust lip (not in 3D version)
8 Remove the 6 pcs
M6x20 flange screws
(B) holding the transmis-
sion cover (A).

CAUTION

On the WD. or WDS.

robots the transmission
cover and sealing is
glued on to the robot
using sealing com-
pound. When removing
the transmission cover
use a screwdriver to
carefully separate the
sealing from the sealing
compound. Carefully
remove the sealing
compound from the ro-
bot and transmission
cover.

xx0700000510

A Transmission cover
B Flange screw M6x20
9 Remove the transmis-
sion cover. Note

Remove the cables to the brake release, described in section

Replacement of brake release button on page 223.

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3 Maintenance
3.5.2 Gearboxes, axes 1- 4
Continued

Action Note
10 Remove the magnetic
plugs and drain the
gearboxes, one by one.

xx0700000511

A Magnetic plugs
B Oil level plug
11
Note

Clean the magnetic

plugs before assemble.

12 Refit the magnetic plug Tightening torque 10-12 Nm.

(A), change the sealing
washers if necessary.
13 The oil is filled through Types and volumes of oil are specified in the Technical refer-
the plug holes (A) with ence manual - Lubrication in gearboxes - 3HAC042927-001.
specified volume,
check oil level by re-
moving the oil level
plug (B).

xx0700000729

Continues on next page

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 3 Maintenance
3.5.2 Gearboxes, axes 1- 4
Continued

Action Note
14 On WD. and WDS.
Clean the cover sealing
upper surface using
ethanol.

Note

Make sure that all old

sealing compound is
removed.

xx1100000543

15 Apply a 5 mm string of
sealing compound on
the sealing upper sur-
face.

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3 Maintenance
3.5.2 Gearboxes, axes 1- 4
Continued

Action Note
16 Refit the transmission
cover using the 6pcs
M6 x 20 hexagon bolt
with flange.
Use locking liquid (loc-
tite 243).

Note

Follow the tightening

sequence in the figure.

xx0800000024

Tightening torque 4 Nm.

17 After tightening, check A
that the sealing com-
pound fills the entire
gap according to figure,
position B. Remove ex-
cessive compound or
fill up if needed.
B

xx1100000540

Continues on next page

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 3 Maintenance
3.5.2 Gearboxes, axes 1- 4
Continued

Action Note
18 Refit the 3 pcs flange Tightening torque 4 Nm.
and the 3 pcs flange
gasket, using the 6 pcs
M6x20. Apply locking
liquid (Loctite 243).
(Change the gaskets if
necessary.)
19 Refit the 3 pcs upper
arm sealing rings. Ap-
ply locking liquid (loc-
tite 243). Change the
sealings if necessary.

xx0700000509

A Screw M6x20
B Flange
20 Refit the 3 upper arms Described in section Replacement of upper arm on page 172.
using the 6 x 3 pcs
M6x40. Apply locking
liquid (loctite 243).
21 Mount new VK-covers Apply locking liquid (loctite 243).
on the upper arms.
22 Refit all parallel arms. Described in section Replacement of parallel arms on page 167.
23 Refit the telescopic Described in section Replacement of telescopic shaft on
shaft. page 182
24 Refit base cover.
CAUTION

The base cover has sharp edges, use protective gloves.

Described in section Replacement of base cover gasket on
page 160

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3 Maintenance
3.6.1 Introduction

3.6 Cleaning activities

3.6.1 Introduction

Washing standards
The manipulator is tested to fulfill the following standards according to
IEC60529:2001.
• Standard: IP54
• Wash down: IP67
• Wash down stainless: IP69K according to ISO 20653:2001
• Clean Room: IP54

Note

The stainless version is not available for the IRB 360 used with OmniCore
controllers.

Cleaning overview

Protection type Cleaning method

Vacuum Wipe with Rinse with wa- High pressure Deter-
Cleaner cloth ter water or steam gents
Standard Yes Yes No No No
Wash down Yes Yes Yes i Yes ii Yes
Wash down stainless Yes Yes Yes Yes iii Yes
Clean room Yes Yes No No No
i It is highly recommended that the water contains a rust-prevention solution.
ii It is highly recommended that the water and steam contains rust preventive, without cleaning
detergents.
iii See recommended water temperature and pressure.

Continues on next page

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 3 Maintenance
3.6.1 Introduction
Continued

Sensitive spots
Sensitive spots for direct flushing.

Note

This applies for IRB 360 WD and IRB 360 WDS versions. If standard version
parts is used in a WD or WDS version robot the robot must be cleaned as a
standard version robot.

xx2100000169

A Base cover gasket E Movable plate

B Brake release button F Upper arm sealing rings
C Transmission cover gasket G Universal joints
D Axis 4 sealing ring

Continues on next page

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3 Maintenance
3.6.1 Introduction
Continued

Cleaning with water and steam

Instructions for rinsing with water
The IRB 360 with protection types Wash down and Wash down stainless can be
cleaned by rinsing with water (water cleaner).
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 700 kN/m2 (7 bar)
• Fan jet nozzle should be used, min. 45° spread
• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum water temperature: 80°C
• Maximum flow: 20 liters/min

Instructions for steam or high pressure water cleaning

The IRB 360 with protection types Wash down and Wash down stainless can be
cleaned using a steam cleaner or high pressure water cleaner.
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 2,500 kN/m2 (25 bar)
• Fan jet nozzle should be used, min. 45° spread
• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum water temperature: 80°C

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 3 Maintenance
3.6.2 Standard cleaning

3.6.2 Standard cleaning

Overview
The standard version of IRB 360 is not manufactured for wash down applications,
and must not be cleaned with water.

Note

If some part of a standard version robot is stainless the robot must still be cleaned
as a standard version robot.

Note

The stainless version is not available for the IRB 360 used with OmniCore
controllers.

Required equipment

Equipment Note
Vacuum cleaner
Cloth

Cleaning instructions

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Action Note
1 Use a vaccum cleaner to remove loose particles.
2 Use a dry or moistened cloth to wipe off the dirt
and dust.

Continues on next page

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3 Maintenance
3.6.2 Standard cleaning
Continued

Optional use of rubber belows - IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600
To simplify cleaning, it is possible to use the spring units without the rubber bellows.

xx0700000707

To remove the rubber bellows, see section Replacement of parallel arms on

page 167.

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 3 Maintenance
3.6.3 Wash down cleaning

3.6.3 Wash down cleaning

Required equipment

Equipment Note
High pressure washer
Cloth

Usable detergents

Detergent Type Old designation

Detergent Topaz LD1 P3-Topax 12
Disinfectant P3-Topax 990 P3-Topax 99

Cleaning instructions

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Action Note
1 Pre-rinse with water for removal • Water temperature: max. 80°C
of rough soil.
See figure for Sensitive spots
on page 137.
2 Foam the whole external surface • Detergent: Topaz LD1,
with detergent. • Concentration: 3 %
• Water temperature: 40 - 60°C
3 Let the detergent work for ap-
prox 20 minutes to retain effect-
ive cleaning properties.
Ensure that the solvent does not
dry on the surface.
4 Rinse thoroughly with water.
5 Apply the disinfectant. Time, • Detergent: P3-topactive DES
concentration, and water temper- • Concentration: 1 - 2%.
ature are chosen to reach the • Water temperature: 10 - 40°C
desired effect.
• Time approx. 20 min.
6 Rinse thoroughly with water.
7 After cleaning bearing races,
swivel cup sealing and sealing
ring (V-ring), lubricate them with
provision classified grease.

Continues on next page

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3 Maintenance
3.6.3 Wash down cleaning
Continued

Action Note
8 If the labels on the robot are Described in section Replacement of labels on
damaged in the cleaning proced- page 206
ure, apply new labels.

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 3 Maintenance
3.6.4 Wash down stainless cleaning

3.6.4 Wash down stainless cleaning

Note

The stainless version is not available for the IRB 360 used with OmniCore
controllers.

Required equipment

Equipment Note
High pressure washer

Usable detergents
The stainless version is verified against the following detergents.
Detergent Type Old designation
Detergent Topaz MD4 Topmaxx 421
Detergent Topaz CL2 P3-topax M 55
Detergent Topaz AC3 P3-topax 56
Disinfectant P3-topactive DES

Cleaning instructions

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Action Note
1 Pre-rinse with water for removal • Water temperature: max. 80°C
of rough soil with low pressure.
See figure for Sensitive spots
on page 137.
2 Foam the whole external surface • Detergent: TOPAZ MD4
with detergent. • Concentration: 3 %
• Water temperature: 40 - 60°C
3 Let the detergent work for ap-
prox 20 minutes to retain effect-
ive cleaning properties.
Ensure that the solvent does not
dry on the surface.
4 Rinse thoroughly with water.

Continues on next page

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3 Maintenance
3.6.4 Wash down stainless cleaning
Continued

Action Note
5 Apply the disinfectant. Time, • Detergent: P3-topactive DES
concentration, and water temper- • Concentration: 1 - 2%.
ature are chosen to reach the • Water temperature: 10 - 40°C
desired effect.
• Time approx. 20 min.
6 Rinse thoroughly with water.
7 After cleaning bearing races,
swivel cup sealing and sealing
ring (V-ring), lubricate them with
provision classified grease.
8 If the labels on the robot are Described in section Replacement of labels on
damaged in the cleaning proced- page 206
ure, apply new labels.

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 3 Maintenance
3.6.5 Clean room cleaning

3.6.5 Clean room cleaning

Required equipment

Equipment Note
Vacuum cleaner
Cloth

Usable detergents

Detergent Note
Light cleaning detergent
Isopropyl alcohol

Cleaning instructions

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Action Note
1 Use a vacuum cleaner to re-
move loose particles.
2 Use a cloth with cleaning deter-
gent or Isopropyl alcohol to wipe
off the dirt and dust.

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3 Maintenance
3.7.1 Measuring backlash axis 4

3.7 Measuring activities

3.7.1 Measuring backlash axis 4

General
This section describes measuring of the backlash on axis 4.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Required equipment and references

Required equipment Note

Indicator clock
Dynamometer
Tool (square tube, length = min. 250 mm)

Measuring backlash

Action Note
1 Attache the tool on manipulator. For fastening of tool on robot, see hole
pattern in Fitting equipment on robot on
page 66.
2 Place the indicator clock on a metallic surface
placed underneath the manipulator.
3 Apply torque 1 Nm, i.e. 10N on a distance of
100 mm from center of rotation.

xx1700000046

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 3 Maintenance
3.7.1 Measuring backlash axis 4
Continued

Action Note
4 Decrease force to 0N.

xx1700000047

5 Apply torque 0,2 Nm, i.e. 2N on a distance of

100 mm from center of rotation.

xx1700000048

6 Register first measurement point.

7 Apply torque 1 Nm in the other direction, i.e.
10 N on a distance of 100 mm from center of
rotation.

xx1700000049

8 Decrease force to 0N.

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3 Maintenance
3.7.1 Measuring backlash axis 4
Continued

Action Note
9 Apply torque 0,2 Nm, i.e. 2 N on a distance of
100 mm from center of rotation.

xx1700000050

10 Register second measurement point.

11 Calculate the angular backlash as the differ-
ence between measurement point 1 and 2 di-
vided by 2πr.

Note

r is the distance from center of rotation to

where the measurement is done.

xx1700000051

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 4 Repair
4.1 Introduction

4 Repair
4.1 Introduction

Structure of this chapter

This chapter describes repair activities for the IRB 360. Each procedure contains
the information required to perform the activity, for example spare parts numbers,
required special tools, and materials.

WARNING

Repair activities not described in this chapter must only be carried out by ABB.

Report replaced units

Note

When replacing a part on the IRB 360, report to your local ABB the serial number,
the article number, and the revision of both the replaced unit and the replacement
unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.

Safety information
Make sure to read through the chapter Safety on page 19 before commencing any
service work.

Note

If the IRB 360 is connected to power, always make sure that the IRB 360 is
connected to protective earth and a residual current device (RCD) before starting
any repair work.
For more information see:
• Product manual - OmniCore C30
• Product manual - IRC5
• Product manual - IRC5 Compact
• Product manual - IRC5 Panel Mounted Controller

Note

The stainless version is not available for the IRB 360 used with OmniCore
controllers.

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4 Repair
4.2.1 Mounting instructions for bearings

4.2 General procedures

4.2.1 Mounting instructions for bearings

General
This section describes how to mount and grease different types of bearings on the
robot.

Equipment

Equipment, etc. Article number Note

Grease Grease specification
on page 261.

Assembly of all bearings

Attend to the following instructions while mounting a bearing on the robot.
Action Note
1 To avoid contamination, let a new bearing remain in its wrapping
until it is time for fitting.
2 Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
3 Bearing rings, inner rings, and roller elements must not be subjec-
ted to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.

Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure must be carried out to
enable the roller elements to adjust to the correct position against the race flange.
Action Note
1 Tension the bearing gradually until the recommended pre-tension is achieved.

Note

The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.

2 Make sure the bearing is properly aligned as this will directly affect the durab-
ility of the bearing.

Greasing of bearings

Note

This instruction is not valid for solid oil bearings.

Continues on next page

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 4 Repair
4.2.1 Mounting instructions for bearings
Continued

The bearings must be greased after assembly according to the following

instructions:
• 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.
Grease the different types of bearings as following description:
• Grooved ball bearings must be filled with grease from both sides.
• Tapered roller bearings and axial needle bearings must be greased in the
split condition.

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4 Repair
4.2.2 Mounting instructions for sealings

4.2.2 Mounting instructions for sealings

General
This section describes how to mount different types of sealings.

Equipment

Consumable Article number Note

Grease Grease specification
on page 261.

Rotating sealings
The procedure below describes how to fit rotating sealings.

CAUTION

Please observe the following before commencing any assembly of sealings:

• Protect the sealing during transport and mounting, especially the main lip.
• Keep the sealing in its original wrappings or protect it well before actual
mounting.
• The fitting of sealings and gears must be carried out on clean workbenches.
• Use a protective sleeve for the main lip during mounting, when sliding over
threads, keyways or other sharp edges.

Action Note
1 Check the sealing to ensure that:
• The sealing is of the correct type.
• There is no damage on the main lip.
2 Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.

Continues on next page

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 4 Repair
4.2.2 Mounting instructions for sealings
Continued

Action Note
3 Lubricate the sealing with grease just before fitting. Article number is specified in
(Not too early - there is a risk of dirt and foreign Equipment on page 152.
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.

A B C
xx2000000071

A Main lip
B Grease
C Dust lip
4 Mount the sealing correctly with a mounting tool. A
Never hammer directly on the sealing as this may
result in leakage.

xx2000000072

A Gap
5 Make sure that no grease is left on the robot surface.

Continues on next page

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4 Repair
4.2.2 Mounting instructions for sealings
Continued

Flange sealings and static sealings

The following procedure describes how to fit flange sealings and static sealings.
Action
1 Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
2 Clean the surfaces properly in accordance with the recommendations of ABB.
3 Distribute the sealing compound evenly over the surface, preferably with a brush.
4 Tighten the screws evenly when fastening the flange joint.

O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.
3 Check the o-ring grooves.
The grooves must be geometrically correct and
should be free of pores and contamination.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Check that the o-ring is not squashed outside
the o-ring groove.
7 Make sure that no grease is left on the robot
surface.

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 4 Repair
4.2.3 Screw joints

4.2.3 Screw joints

General
This section describes how to tighten the various types of screw joints on ABB
robots.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the
screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating
disappears. After this the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber
type should be used.

Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!

Oil-lubricated screws with slotted or cross-recess head screws

Note

A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with allen head screws.

Note

A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.

Continues on next page

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4 Repair
4.2.3 Screw joints
Continued

Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670
M24 680 960 1150

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.

Note

A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M8 28 35
M10 55 70
M12 96 120
M16 235 280
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors

The following table specifies the recommended standard tightening torque for
water and air connectors when one or both connectors are made of brass.

Note

A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.

Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm -

Nominal Min. Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25

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 4 Repair
4.2.3 Screw joints
Continued

Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm -

Nominal Min. Max.
1/2 40 30 50
3/4 70 55 90

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4 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts

4.2.4 Cut the paint or surface on the robot before replacing parts

General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
When replacing parts on a robot with protection type Clean Room, it is important
to make sure that after the replacement, no particles will be emitted from the joint
between the structure and the new part, and that the easy cleaned surface is
retained.

Required equipment

Equipment Spare parts Note

Sealing compound 3HAC073510-001 Trans7
Tooling pin Width 6-9 mm, made of wood.
Cleaning agent Ethanol
Knife
Lint free cloth
Touch up paint Clean Room 3HAC036639-001 White

Removing

Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.

xx0900000121

2 Carefully grind the paint edge that is left on

the structure to a smooth surface.

Refitting

Action Description
1 Before the parts are refitted, clean the joint Use ethanol on a lint free cloth.
so that it is free from oil and grease.
2 Place the tooling pin in hot water.

Continues on next page

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 4 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts
Continued

Action Description
3 Seal all refitted joints with sealing compound.

xx0900000122

4 Use the tooling pin to even out the surface

of the sealing compound.

xx0900000125

5 Use Touch up paint Clean Room, white to 3HAC036639-001

paint any damaged surfaces.

Note

Always read the instruction in the product

data sheet in the paint repair kit for Clean
Room.

Note

After all repair work, wipe the robot free from particles with spirit on a lint free
cloth.

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4 Repair
4.3.1 Replacement of base cover gasket

4.3 Complete robot

4.3.1 Replacement of base cover gasket

General
This section describes how to replace the base cover gasket.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Continues on next page

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 4 Repair
4.3.1 Replacement of base cover gasket
Continued

Location and tightening sequence

xx0700000553

A Base cover
B Hollow o-ring (Base cover)
C Flange screw M6x20 (12 pcs)
D Plastic washer (12 pcs)
E Rubber gasket (12 pcs)

Required equipment and references

Equipment Spare part number Note

Hollow o-ring (base cov- See Product manual, spare
er) parts - IRB 360.
Standard tools Standard toolkit on page 258
Plastic washer See Product manual, spare
parts - IRB 360.
Rubber gasket See Product manual, spare
parts - IRB 360.

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.
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4 Repair
4.3.1 Replacement of base cover gasket
Continued

Removal

Action Note
1 Remove the flange screws and washers and check If necessary, change them.
them.
2 Remove the base cover.
CAUTION

The base cover has sharp edges,

use protective gloves.

3 Remove and discard the hollow o-ring. See article number in Product
manual, spare parts - IRB 360.
4 Remove and discard the rubber gaskets. See article number in Product
manual, spare parts - IRB 360.

Refitting

Action Note
1 Refit new rubber gaskets.
2 Refit a new hollow o-ring.
Note

Do not lubricate the hollow o-ring

for the base cover, it can slip out
of position when cleaning.

3 Refit the base cover.

CAUTION

The base cover has sharp edges,

use protective gloves.

4 Refit the flange screws with plastic washers. See tightening sequence Location
and tightening sequence on
Note page 161.
Use tightening torque 4 Nm for
Check that the washers are not damaged. Replace both rounds.
if needed.

Note

Always tighten the base cover screws in two rounds.

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 4 Repair
4.3.2 Replacement of serial measurement board

4.3.2 Replacement of serial measurement board

General
This section describes how to replace the SMB unit (serial measurement board).

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Continues on next page

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4 Repair
4.3.2 Replacement of serial measurement board
Continued

Location

DSQC 633A RMU 101

D

D
E

C
B

xx1300000354

A SMB unit
B Bracket SMB unit
C 3 pcs flange screw M6 x 20
D SMB battery
E SMB battery contact (X3)

Required equipment and references

Note

There are different variants of SMB units and batteries. The variant with the
3-pole battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!

Equipment Spare part no. Note

Standard tools Standard toolkit on
page 258

Continues on next page

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 4 Repair
4.3.2 Replacement of serial measurement board
Continued

Equipment Spare part no. Note

Serial measurement unit See Product manual,
spare parts - IRB 360.
Base cover gasket See Product manual, (If damaged)
spare parts - IRB 360.
Plastic washer See Product manual, (If damaged)
spare parts - IRB 360.

References
Circuit diagram - IRB 360
Updating revolution counters on page 241.
Replacement of base cover gasket on page 160

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Removal SMB unit

Action Note
1 Remove the base cover. Described in section Replacement
of base cover gasket on page 160
2 Remove the three(3) flange screws holding the Use standard tools
bracket for the SMB unit.
3 Disconnect all the cables from the SMB unit.
4 Remove the SMB unit.

Note

This product contains certain materials considered hazardous. This product must
be disposed of in accordance with the current legislation of the country in which
the robot and control unit is installed.

Refitting SMB unit

Note

Check the new battery, using a voltameter. It should read approx +12V.

Action Note
1 Refit the new SMB unit.
2 Connect all cables. As described in circuit diagram
3HAC028647-009
3 Refit the bracket using the three(3) flange screws. Tightening torque 4 Nm
4 Refit the base cover. Described in section Replacement
of base cover gasket on page 160

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4 Repair
4.3.2 Replacement of serial measurement board
Continued

Action Note
5 Update the revolution counters. Described in section Updating re-
volution counters on page 241

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 4 Repair
4.3.3 Replacement of parallel arms

4.3.3 Replacement of parallel arms

General
This section describes how to change the parallel arms.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Location
IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600

xx0700000488

A Upper arm
B Parallel arm
C Spring unit
D Bearing ring

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4 Repair
4.3.3 Replacement of parallel arms
Continued

IRB 360 - 8/1130, IRB 360 - 6/1600

xx1300000163

A Upper arm
B Parallel arm
C Spring unit
D Bearing ring

Required equipment and references

Equipment Spare part no. Note

Standard tools Standard toolkit on page 258
Pliers for parallel arms 3HAC6194-1
Parallel arms See Product manual, spare
parts - IRB 360.

References
Spring units on page 113
Special tools on page 259

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Continues on next page

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 4 Repair
4.3.3 Replacement of parallel arms
Continued

Removing the parallel arms

Illustrations

CAUTION

Never use unnecessary force when removing the springs. Only work on one side
or the spring will be overstressed.

xx0700000525

xx0700000555

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4 Repair
4.3.3 Replacement of parallel arms
Continued

Removing the parallel arms

Use the procedure to remove the parallel arms.
Action Note
1 Remove the parallel arms by using the pliers, either Use the pliers according to Illustra-
on the left side or the right side, not both. tions on page 169.
Article number is specified in Re-
quired equipment and references
on page 168.

Note

Press with the tool on the alumini-

um surface, not on the carbon
fiber, or the parallel arms may be
damaged.

2 Remove the springs. By hand.

Refitting the parallel arms

CAUTION

Never use unnecessary force when refitting the springs. Only work on one side
or the spring will be overstressed.

Refitting the parallel arms

Use the procedure to refit the parallel arms.
Action Note
1 Fit the springs on the parallel arms. By hand. Apply grease according
to section Spring units on page 113
2 Refit the parallel arm to the upper arm by using the Use the pliers according to Illustra-
pliers, either on the left side or the right side, not tions on page 169.
both. Article number is specified in Re-
quired equipment and references
on page 168.

Note

Press with the tool on the alumini-

um surface, not on the carbon
fiber, or the parallel arms may be
damaged.

3 Refit the parallel arm to the movable plate by using Use the pliers according to Illustra-
the pliers, either on the left side or the right side, tions on page 169.
not both. Article number is specified in Re-
quired equipment and references
on page 168.

Note

Always mount the movable plate

with the axis 4 calibration mark in
direction axis 1.

Continues on next page

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 4 Repair
4.3.3 Replacement of parallel arms
Continued

Action Note
4 Recalibrate the robot. See Calibration information on
page 227.

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4 Repair
4.3.4 Replacement of upper arm

4.3.4 Replacement of upper arm

General
This section describes replacement of upper arm.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Location

A
xx0700000595

A VK- cover
B 6x hex socket head cap screw M6 x 40 (12.9 gleitmo) and 6x plain washer
6.4x12x1.6 steel A2-F

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4.3.4 Replacement of upper arm
Continued

Required equipment and references

Equipment Spare part No. Note

Standard tools Standard toolkit on page 258
Upper arm See Product manual, spare
parts - IRB 360.
Sealing ring See Product manual, spare
parts - IRB 360.
Flange gasket ax.1-3 See Product manual, spare
parts - IRB 360.
VK-cover See Product manual, spare
parts - IRB 360.
Locking liquid Loctite 243

References
Standard toolkit on page 258
Replacement of parallel arms on page 167
Mounting instructions for sealings on page 152

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Removal

Action Note
1 Remove the parallel arm Described in section Replacement of parallel arms on
on the specific upper arm. page 167
2 Remove the VK-cover Use a screwdriver.
3 Remove the six screws 6x Hex socket head cap screw M6 x 40 (12.9 gleitmo) and
6x plain washer 6.4x12x1.6 Steel A2-F
4 Remove the upper arm.
5
Note

Always check the condi-

tion of the sealing ring
and the flange gasket

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4 Repair
4.3.4 Replacement of upper arm
Continued

Action Note
6 Remove the two
flangescrews (B) holding
the flange (C). If neces-
sary, change the sealing
ring (A) and the flange
gasket (D).

Note

Do not use the sealing

ring (A) on robots with
protection Clean Room or
Stainless Clean Room.

xx0700000601

Refitting

Action Note
1 Refit the flange with the new mounted sealing ring, Tightening torque 4 Nm.
using the two screws with Loctite 243 and the new
flange gasket.

Tip

Mounting instructions for sealings on page 152

2 Refit the upper arm using the 6x hex socket head Tightening torque 11 Nm.
cap screw M6 x 40 (12.9 Gleitmo) and 6x plain
washer 6.4x12x1.6 steel A2-F.
3 Fit a new VK-cover. By hand.
4 Refit the parallel arm. Described in section Replacement
of parallel arms on page 167.
5 Recalibrate the robot. See Calibration information on
page 227.

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 4 Repair
4.3.5 Replacement of bearing rings

4.3.5 Replacement of bearing rings

General
This section describes how to change bearing rings in the parallel arms.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Required equipment and references

Equipment Spare part no. Note

Bearing ring See Product manual, spare
parts - IRB 360.
Standard tools Standard toolkit on page 258.
Drifter Only required for robot ver-
sions: IRB 360 - 1/800, IRB
Dolly 360 - 1/1130, IRB 360 - 3/1130
and IRB 360 - 1/1600.
Special tools on page 259
Pliers for parallel arms Special tools on page 259
Grease - Valid for robot versions: IRB
360 - 1/1130, IRB 360 -
3/1130, IRB 360 - 1/800, IRB
360 - 1/1600.
Required for non-mainten-
ance free bearing rings.
• Mobilgrease FM 102
• Optimol Obeen UF 2
See Different versions of
bearing rings require different
maintenance procedures on
page 104.

References
Replacement of parallel arms on page 167
Special tools on page 259

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Continues on next page

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4 Repair
4.3.5 Replacement of bearing rings
Continued

CAUTION

Never use unnecessary force when removing the springs. Only work on one side
or the spring will be overstressed.

Removal

Action Note
1 Remove the parallel arms According to section Replacement of parallel arms on
by hand or using tool, left page 167.
or right side, not both.
2 Remove the bearing ring
using a screwdriver.

xx0700000486

Refitting

CAUTION

Never use unnecessary force when refitting the springs. Only work on one side
or the spring will be overstressed.

Action Note
1 Place a new bearing ring into the joint socket.

Continues on next page

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 4 Repair
4.3.5 Replacement of bearing rings
Continued

Action Note
2 Valid for robot versions: IRB 360 - 1/1130, IRB 360
- 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600.
1 Place the parallel arm in the dolly.
2 Put the drifter into the bearing ring and knock
it gently down to its resting position.
3 Lubricate bearing rings that are not mainten-
ance-free (see Different versions of bearing
rings require different maintenance proced-
ures on page 104).

xx0700000524

A Parallel arm
B Bearing ring
C Drifter
D Dolly
Type of grease for non-mainten-
ance-free bearing rings, see Re-
quired equipment and references
on page 175.
3 Valid for robot versions: IRB 360 - 8/1130, IRB 360
- 6/1600.
Push the bearing ring into its resting position by
hand.
4 Refit the parallel arms to the upper arm, left or right By hand or using tool according
side, not both. to section Replacement of parallel
arms on page 167
5 Run the robot for six (6) hours for the bearing rings
to wear in.
6 Wipe clean the joint balls and the bearing rings.

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4 Repair
4.3.6 Replacement of movable plate

4.3.6 Replacement of movable plate

General
This section describes how to replace the movable plate.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Location
IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600

B
A
C

xx0700000532

A Universal joint
B Set screw, dog point
C Sealing ring (V-ring)

Continues on next page

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 4 Repair
4.3.6 Replacement of movable plate
Continued

IRB 360 - 8/1130, IRB 360 - 6/1600

xx1300000165

A Universal joint
B Set screw, dog point
C V-ring sealing (transparent in the figure)

Required equipment and references

Equipment Spare part number Note

Spare parts, movable plate See Product manual, spare
parts - IRB 360.
Locking liquid - Loctite 243.
Standard tools - Standard toolkit on page 258

References
Replacement of parallel arms on page 167
Replacement of vacuum hoses on page 211

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Continues on next page

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4 Repair
4.3.6 Replacement of movable plate
Continued

Removal

CAUTION

The spring units must be removed according to the description in section

Replacement of parallel arms on page 167or they will be damaged.

Action Note
1 Remove all air / vacuum hoses from the Described in section Replacement of vacu-
swivel cup on the movable plate. um hoses on page 211
2 Remove all three parallel arms from the Described in section Replacement of parallel
movable plate. arms on page 167.
3 Hold the movable plate while raising the Use standard tools.
sealing ring (C) and removing the set
screw (B) that locks the universal joint.
Remove the movable plate from the tele-
scopic shaft.

Calibration mark, axis 4

IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600

xx0700000629

A Axis 4 calibration mark

IRB 360 - 8/1130, IRB 360 - 6/1600

Continues on next page

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 4 Repair
4.3.6 Replacement of movable plate
Continued

Refitting

CAUTION

Never use unnecessary force when refitting the springs. Only work on one side
or the spring will be overstressed.

Action Note
1 For robot versions IRB 360 - 8/1130, IRB 360 -
6/1600:
Check the radial seal.

xx1300000202

2 Refit the movable plate to the telescopic shaft and Use standard tools.
lock the universal joint by refitting the set screw (B).
Use locking liquid (Loctite 243).

xx0700000613

Tightening torque for set screw

3HAC12846-2 (M6x16 A2): 7 Nm
Tightening torque for set screw
3HAC12846-3 (M6x16 FZB): 9.5
Nm
Tightening torque for set screw
3HAC12846-4 (M6x16 A4): 8.5 Nm

Tip

Use a 90° angled bit holder.

3 Push the sealing ring (C) back in place.

4 Refit the parallel arms to the movable plate. Described in section Replacement
of parallel arms on page 167
5 Refit the air / vacuum hoses to the swivel cup on Described in section Replacement
the movable plate. of vacuum hoses on page 211.

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4 Repair
4.3.7 Replacement of telescopic shaft

4.3.7 Replacement of telescopic shaft

General
This section describes how to change the telescopic shaft.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Location

xx0700000538

A Telescopic shaft
B Set screw

Required equipment and references

Equipment Spare part no. Note

Standard tools Standard toolkit on page 258

Continues on next page

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 4 Repair
4.3.7 Replacement of telescopic shaft
Continued

Equipment Spare part no. Note

Telescopic shaft See Product manual, spare
parts - IRB 360.
Universal joint See Product manual, spare
parts - IRB 360.
90° angled bit holder
Locking liquid Loctite 243

References
Replacement of parallel arms on page 167
Replacement of movable plate on page 178

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Removal

Action Note
1 Remove the parallel Described in section Replacement of parallel arms on
arms. page 167
2 Remove the movable Described in section Replacement of movable plate on
plate. page 178
3 Remove the upper set
screw.

xx0700000612

Tip

Use a 90° angled bit holder.

4 Remove the telescopic

shaft.

Refitting

Action Note
1 Refit the telescopic shaft.

Continues on next page

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4 Repair
4.3.7 Replacement of telescopic shaft
Continued

Action Note
2 Refit the upper set
screw, use locking liquid
(Loctite 243).

xx0700000613

Tightening torque for set screw 3HAC12846-2 (M6x16 A2):

• 7 Nm.
Tightening torque for set screw 3HAC12846-3 (M6x16 FZB):
• 9.5 Nm.
Tightening torque for set screw 3HAC12846-4 (M6x16 A4):
• 8.5 Nm.

Tip

Use a 90° angled bit holder.

3 Refit the movable plate, Described in section Replacement of movable plate on

use locking liquid (Loc- page 178.
tite 243).
4 Refit the parallel arms. Described in section Replacement of parallel arms on
page 167.

184 Product manual - IRB 360

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 4 Repair
4.3.8 Replacement of universal joint

4.3.8 Replacement of universal joint

General
This section describes how to change the universal joint.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Location

xx0800000020

Required equipment and references

Equipment Spare part no. Note

Standard tools Standard toolkit on page 258.
Locking liquid Loctite 243
Universal joint See Product manual, spare
parts - IRB 360.

Continues on next page

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4 Repair
4.3.8 Replacement of universal joint
Continued

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Removal

Action Note
1 Remove the telescopic shaft. See section Replacement of telescopic shaft on
page 182.
2 Remove the set screw locking Use standard tools.
the universal joint on the tele-
scopic shaft.
3 Remove the universal joint.

Refitting

Action Note
1 Refit the universal joint. Use locking liquid (Loctite 243).
2 Refit the set screw in order to Use locking liquid (Loctite 243).
lock the universal joint to the Tightening torque for set screw 3HAC12846-2
telescopic shaft. (M16x6 A2):
• 7 Nm.
Tightening torque for set screw 3HAC12846-3
(M16x6 FZB):
• 9.5 Nm.
Tightening torque for set screw 3HAC12846-4
(M16x6 A4):
• 8.5 Nm.
3 Refit the telescopic shaft. See section Replacement of telescopic shaft on
page 182.

186 Product manual - IRB 360

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 4 Repair
4.3.9 Replacement of joint balls

4.3.9 Replacement of joint balls

General
This section describes how to change the joint balls.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Location

xx0700000534

A Joint ball
B Joint ball

Required equipment and references

Equipment Spare part no. Note

Standard tools Standard toolkit on page 258
Joint ball See Product manual, spare
parts - IRB 360.
Pliers for parallel arms 3HAC6194-1
Locking liquid Loctite 243
Continues on next page
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4 Repair
4.3.9 Replacement of joint balls
Continued

Equipment Spare part no. Note

Activator Loctite 7649

References
Replacement of parallel arms on page 167
Replacement of movable plate on page 178

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Removal

xx0700000500

A Movable plate
B Joint ball movable plate

CAUTION

Never use unnecessary force when removing the springs. Only work on one side
or the spring will be overstressed.

Action Note
1 Remove the parallel arms. Described in section Replacement
of parallel arms on page 167.
2 Remove the movable plate. Described in section Replacement
of movable plate on page 178
3 Remove the joint balls. Use standard tools.

Note

Locking liquid secures the joint balls to the movable

plate. A heat gun must be used if the movable plate
is stainless, for other materials it is optional. Do not
aim the heat on plastic parts.

Continues on next page

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 4 Repair
4.3.9 Replacement of joint balls
Continued

Refitting

CAUTION

Never use unnecessary force when refitting the springs. Only work on one side
or the spring will be overstressed.

Action Note
1 Refit the joint balls using loctite 243. For the best Tightening torque 11 Nm.
result, use spray activator (Loctite 7649) on the
stainless joint balls.
2 Refit the movable plate. Described in section Replacement
of movable plate on page 178.
3 Refit the parallel arms. Described in section Replacement
of parallel arms on page 167.
4 Run the robot for six (6) hours for the bearing rings
to wear in.
5 Wipe clean the joint balls and the bearing rings.

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4 Repair
4.3.10 Replacement of gearbox unit 1- 3

4.3.10 Replacement of gearbox unit 1- 3

General
This section describes replacing gearbox 1-3 with motor (gearbox unit).

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Note

This action demands standard calibration of the robot. Described in section

Calibration method on page 228.

Continues on next page

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 4 Repair
4.3.10 Replacement of gearbox unit 1- 3
Continued

Location

E C
D

F
B

xx0700000540

A Gearbox ax 1
B Motor ax 1
C Gearbox ax 2
D Motor ax 2
E Gearbox ax 3
F Motor ax 3

Required equipment and references

Equipment Spare part no. Note

Standard tools Standard toolkit on page 258.
Gearbox with motor (axes 1- See Product manual, spare
3) parts - IRB 360.
Gaskets See Product manual, spare
parts - IRB 360.

References
Gearboxes, axes 1- 4 on page 127
Circuit diagram 3HAC028647-009
Calibration method on page 228

Continues on next page

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4 Repair
4.3.10 Replacement of gearbox unit 1- 3
Continued

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Removal

Action Note
1 Remove arm system. Replacement of bearing rings on page 175
2 Remove the transmission Described in section Gearboxes, axes 1- 4 on page 127,
cover Method 2.
3 Remove the base cover Described in section Replacement of base cover gasket
on page 160
4 Disconnect the motor con-
nectors, R3.FB1-3 and
R3.MP1-3.
5 Remove the four hex sock- Described in section Gearboxes, axes 1- 4 on page 127,
et head cap screw M10 x Method 2.
30 with washers.

WARNING

This action will loosen the

gearbox unit weight 16 kg.

xx0700000539

A Hex socket head cap screw M10 x 30

B Plain washer 16.5x20x2 steel A3F

Refitting

Action Note
1 Refit the gearbox unit, using the four hex socket Tightening torque 33 Nm.
head cap screw M10 x 30 with washer 16.5x20x2
steel A3F.

Note

Gearbox unit weight 16 Kg.

Continues on next page

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 4 Repair
4.3.10 Replacement of gearbox unit 1- 3
Continued

Action Note
2 Connect the motor connectors, R3.FB1-3 and Described in circuit diagram, see
R3.MP1-3. Circuit diagram - IRB 360,
3HAC028647-009.
3 Refit the base cover Described in section Replacement
of base cover gasket on page 160
4 Refit the transmission cover. Described in section Gearboxes,
axes 1- 4 on page 127, Method 2.
5 Refit the arm system. Described in section Gearboxes,
axes 1- 4 on page 127, Method 2.
6 Recalibrate the robot. See Calibration information on
page 227.

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4 Repair
4.3.11 Replacement of gearbox unit 4

4.3.11 Replacement of gearbox unit 4

General
This section describes replacing gearbox 4 with motor (gearbox unit)

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Note

This action demands standard calibration of the robot. Described in section

Calibration method on page 228.

Continues on next page

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 4 Repair
4.3.11 Replacement of gearbox unit 4
Continued

Location

xx0700000547

A Gearbox motor axis 4

B Hexagon socket head screw 3x (M6x25) with plain washer 6,4x12x1,6 steel A2F
C Gearbox axis 4
D Sealing ring w. dust lip

Required equipment and references

Equipment Spare Part No. Note

Gearbox unit axis 4 See Product manual, spare
parts - IRB 360.
Standard tools Standard toolkit on page 258.
Sealing rings See Product manual, spare
parts - IRB 360.
Locking liquid Loctite 243

References
Replacement of telescopic shaft on page 182
Replacement of base cover gasket on page 160

Continues on next page

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4 Repair
4.3.11 Replacement of gearbox unit 4
Continued

References
Calibration method on page 228

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Removal

Action Note
1 Remove the (12 pcs) M6 flange screws holding the Use standard tools. Described in
base cover. section Replacement of base
cover gasket on page 160
2 Disconnect the motor connectors: R3.FB4 and
R3.MP4.
3 Remove the telescopic shaft. Described in section Replacement
of telescopic shaft on page 182.
4 Remove the 3x hexagon socket head screw (M6x25) Shown in figure
with plain washer 6,4x12x1,6 steel A2F(B).
5 Remove the gearbox unit axis 4.
6 Remove the sealing ring w. dust lip.

Refitting

Action Note
1 Refit a new sealing ring, apply grease. See section Grease on sealings
on page 262.
2 Refit the axis 4 gearbox unit.
3 Refit the 3x hexagon socket head screw (M6x25) Tightening torque 9 Nm.
with plain washer 6,4x12x1,6 steel A2F(B).
4 Refit the telescopic shaft. Described in section Replacement
of telescopic shaft on page 182.
5 Reconnect the motor connectors, R3.FB4 and
R3.MP4.
6 Refit the (12 pcs) M6 screws holding the base cover. Use standard tools. Described in
section Replacement of base
cover gasket on page 160
7 Calibrate the robot. Described in section Calibration
information on page 227.

196 Product manual - IRB 360

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 4 Repair
4.3.12 Replacement of motor axis 1-3

4.3.12 Replacement of motor axis 1-3

General
This section describes replacement of motor axis 1-3.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Note

This action demands standard calibration of the robot. Described in section

Calibration method on page 228.

Continues on next page

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4 Repair
4.3.12 Replacement of motor axis 1-3
Continued

Location

xx0700000541

A Motor 1-3
B Gearbox 1-3
C Hex socket head cap screw M6x20 8.8 gleitmo605
D Washer 6,4x12x1,6 steel A2F
E Nitrile rubber O-ring 67,5x3,0
F Oil plug
G Oil plug (upper oil level hole)
H Oil plug
I Gear Z1/1-3, 16 cog

Continues on next page

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 4 Repair
4.3.12 Replacement of motor axis 1-3
Continued

Required equipment and references

Equipment Spare part no. Note

Standard tools Standard toolkit on
page 258
O-ring See Product manual, spare
parts - IRB 360.
AC motor See Product manual, spare
parts - IRB 360.
Locking liquid Loctite 243

References
Replacement of gearbox unit 1- 3 on page 190
Grease specification on page 261

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Removal

Action Note
1 Remove the gearbox unit 1-3. Described in section Replacement of gearbox unit
1- 3 on page 190.
2 Unscrew the three screws (C) Shown in figure Location on page 198
holding the motor.
3 Remove the motor.
DANGER

Oil will be running out of the motor attachment hole

when removing the motor! The oil can be hot. Take
any necessary measures to collect the oil.

Continues on next page

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4 Repair
4.3.12 Replacement of motor axis 1-3
Continued

Refitting

A
B
xx0700000616

A Motor pinion
B Gear Z2/1-3, 90 cog

Action Note
1 Fit a new O-ring (E) onto Shown in figure Location on page 198.
the motor flange, lubricate
the o-ring with grease
FM222.

Continues on next page

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 4 Repair
4.3.12 Replacement of motor axis 1-3
Continued

Action Note
2 Insert the new motor, do
not tighten the screws. CAUTION

Fit the motor, making sure the motor pinion is properly

mated to the gear wheel, do not use force or the motor
pinion may get damaged.

3 Refit the upper arm tempor-

arily, to be used to feel the
backlash.
4 Push on the motor flange
gently in direction A, at the
same time as you feel for
the backlash by moving
the upper arm back and
forward.

xx0700000620

5 Ensure that the gear is Shown in figure Location on page 198

kept absolutely still. Apply Tightening torque 9 Nm.
loctite 243 and tighten the
screws (C).
6 Check through the upper Shown in figure Refitting on page 200.
oil level hole that gear
wheel (B) is axially mov-
able
7 Fill the gearbox with oil. Specified in section Grease specification on page 261.
8 Refit the gearbox unit 1-3 Described in section Replacement of gearbox unit 1- 3 on
page 190.
9 Recalibrate the robot. See Calibration information on page 227.

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4 Repair
4.3.13 Replacement of motor axis 4

4.3.13 Replacement of motor axis 4

General
This section describes replacement of motor axis 4.

Note

This action demands standard calibration of the robot. Described in section

Calibration method on page 228.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

Continues on next page

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 4 Repair
4.3.13 Replacement of motor axis 4
Continued

Location

xx1700001146

A Gearbox axis 4
B Rotational ac motor
C O-ring, nitrile rubber
D Hex socket head cap screw M6x25 8.8
E Washer 6,4x12x1,6 A2F
F Oil plug

Continues on next page

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4 Repair
4.3.13 Replacement of motor axis 4
Continued

Required equipment and references

Equipment Spare part no. Note

Standard tools Standard toolkit on
page 258
O-ring, nitrile rubber See Product manual, spare
parts - IRB 360.
Loctite 243 See Product manual, spare
parts - IRB 360.

References
Replacement of base cover gasket on page 160
Replacement of gearbox unit 4 on page 194
Standard toolkit on page 258
Grease specification on page 261

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Removal

Action Note
1 Remove the base cover. See Replacement of base cover gasket on
page 160.
2 Remove the gearbox with motor. See Replacement of gearbox unit 4 on
page 194.
3 Remove the oil plug, and drain the oil.

xx0700000728

Continues on next page

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 4 Repair
4.3.13 Replacement of motor axis 4
Continued

Action Note
4 Remove the motor.
DANGER

Oil will be running out of the motor attach-

ment hole when removing the motor! The
oil can be hot. Take any necessary meas-
ures to collect the oil.

Refitting

Action Note
1 Fit the new o-ring (C) onto the motor Lubrication specified in section Grease
flange, lubricate the o-ring with grease FM specification on page 261.
222.
2 Insert the new motor, do not tighten the
screws. CAUTION

Fit the motor, making sure the motor pinion

is properly mated to the gear wheel, do not
use force or the motor pinion may get
damaged.

3 Push on the motor flange gently in direc-

tion A, at the same time as you feel for the
backlash by moving the outgoing axis (B)
back and forward.

xx0700000621

4 Make sure that the gear is kept absolutely Tightening torque: 10 Nm

still. Apply Loctite 243 and tighten the
screw (D). In figure Location on page 203.
5 Check the play again. If there is a backlash, loosen the screws
(D) and go back to step 3.
6 Fill the gearbox with oil. Lubrication specified in section Grease
specification on page 261.
7 Refit the gear box with motor. Described in section Replacement of
gearbox unit 4 on page 194.
8 Refit the base cover. Described in section Replacement of base
cover gasket on page 160.

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4 Repair
4.3.14 Replacement of labels

4.3.14 Replacement of labels

General
This section describes replacement and positioning of labels on the IRB 360.

Label positioning

Axis 2 11

11 Axis 1

11

5
Axis 3
SECTION A-A
xx0700000691

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 4 Repair
4.3.14 Replacement of labels
Continued

13 10 13

25
13
(Axis 1)
(Axis 2)

10

1 (Axis 1)

8 9 7

C 3 7
6
05

12

SECTION C-C
6
C 05

xx0700000692

1 Label, Flex Picker-red 190x23

2 ABB-Logotype 69x157
3 Calibration values
5 Instruction plate (brake release)
6 Warning sign 24x21 (electric warning)
7 Rating label
8 UL-label 70x35
9 UL-label 70x35
10 Cleanroom Logotype
11 Axis marks
12 Instruction plate
13 Transport protection label

Required equipment and references

Equipment Spare part no. Note

Label-set See Product manual, spare
parts - IRB 360.

Continues on next page

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4.3.14 Replacement of labels
Continued

Assemble

Action Note
1 Make sure the surface is clean.
2 Assemble the labels according to the illustrations.

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 4 Repair
4.3.15 Replacing of calibration marks

4.3.15 Replacing of calibration marks

Overview
This section describes replacement of calibration marks on an IRB 360.
Replace a calibration mark if it is damaged.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

CAUTION

Always read the specific instructions for Clean Room robots before doing any
repair work, see Cut the paint or surface on the robot before replacing parts on
page 158.

Location

xx2000002386

A Dowel for calibration mark

B Calibration mark (plastic)
C 2 pcs M5 prevailing torque type hexagon nut non metallic insert style1.

Continues on next page

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4 Repair
4.3.15 Replacing of calibration marks
Continued

Required equipment and references

Equipment Spare part no. Note

Standard tools Standard toolkit on page 258.
Calibration mark See Product manual, spare
parts - IRB 360.

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Remove

Action Note
1 Remove the two M5 nuts. Use standard tools.
2 Remove the calibration mark.

Refitting

Action Note
1 Refit a new calibration mark.
2 Refit the two M5 nuts. Tightening torque 4Nm.

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 4 Repair
4.4.1 Replacement of vacuum hoses

4.4 Vacuum system

4.4.1 Replacement of vacuum hoses

General
This section describes replacement of hoses in the vacuum system.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

CAUTION

Always read the specific instructions for Clean Room robots before doing any
repair work, see Cut the paint or surface on the robot before replacing parts on
page 158.

Continues on next page

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4 Repair
4.4.1 Replacement of vacuum hoses
Continued

Location

xx0700000499

A Air filter inlet.

B Ejector unit
C Air filter inlet vacuum.
D Swivel cup
E Hose clamp

Required equipment

Equipment Spare part no. Note

Standard tools
Spare hose set

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Removal

Action Note
1 Open all straps.
2 Pull the hose out from the swivel.
3 Pull the hose out from the air filter.

Refitting

Action Note
1 Fit a new hose on the swivel.

Continues on next page

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4.4.1 Replacement of vacuum hoses
Continued

Action Note
2 Fix the hose, do not tighten, against the three
clamps on the parallel arm.
3 Twist the hose and fit it on the air filter.
4 Adjust the hose.
5 Tighten the straps.
6 Make a small program (low velocity) and check that
the hose runs freely.
7 Fit a new hose on the swivel.
8 Fix the hose, do not tighten, against the three
clamps on the parallel arm.

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4 Repair
4.4.2 Draining of water separation filter

4.4.2 Draining of water separation filter

General
This section describes:
• Air filter change in the vacuum system
• Emptying water separation filter

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

CAUTION

Always read the specific instructions for Clean Room robots before doing any
repair work, see Cut the paint or surface on the robot before replacing parts on
page 158.

Location

xx0700000544

A Air filter (comp)

B Air filter (Vac)
C Water separation bottom nipple

Continues on next page

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 4 Repair
4.4.2 Draining of water separation filter
Continued

Removal water

Action
1 Drain the water separation filter, opening the bottom nipple (C).

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4 Repair
4.4.3 Replacement of ejector unit

4.4.3 Replacement of ejector unit

General
This section describes replacement of ejector unit.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

CAUTION

Always read the specific instructions for Clean Room robots before doing any
repair work, see Cut the paint or surface on the robot before replacing parts on
page 158.

Continues on next page

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 4 Repair
4.4.3 Replacement of ejector unit
Continued

Location

xx0700000714

A Attachment
B Bracket
C Hexagon head screw, M8x35 (Steel 8.8-A2F)
D Ejector unit
E Hexagon bolt with flange, M6 x 20 (A2 DIN6921)
F Gasket

Required equipment and references

Equipment Spare part no. Note

Standard tools
Spare parts Spare parts, ejector unit.

References
Spare parts, ejector unit.
Replacement of base cover gasket on page 160.

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Continues on next page

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4 Repair
4.4.3 Replacement of ejector unit
Continued

Illustration

xx0700000704

A Hexagon bolt with flange M6x20 (A2 DIN6921)

B Nuts for the air nozzles
C Ejector unit
D Front plate
E Gasket
F Pressure guard nut
G Pressure guard cap

Removal

Action Note
1 Disconnect the air supply, vacuum hoses, and signal
cable from the ejector unit.
2 Remove the base cover. Described in section Replacement
of base cover gasket on page 160.
3 Remove the 2x hexagon socket head cap screw Use standard tools.
M8x35 holding the filter holder, and remove the fil-
ters.
4 Remove all the nuts for the air nozzles, pressure
guard cap and the pressure guard nut.
5 Remove the ejector unit inwards direction.

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 4 Repair
4.4.3 Replacement of ejector unit
Continued

Action Note
6 Remove the 4x hexagon bolt with flange M6x20
holding the front plate, and remove the plate and
the gasket.

Refitting

Action Note
1 Refit the front plate and the gasket using the 4x Tightening torque 4 Nm.
hexagon bolt with flange M6x20. (if needed, replace
the gasket)
2 Refit the ejector unit from the inside.
3 Refit all the nuts for the air nozzles, pressure guard Tightening torque 4 Nm.
cap and the pressure guard nut.
4 Refit the filters using the 2x hexagon socket head Use standard tools.
cap screw M8x35.
5 Reconnect the air supply, vacuum hoses and signal
cable from the ejector unit.
6 Refit the base cover. Replacement of base cover gas-
ket on page 160

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4 Repair
4.5.1 Replacement of cable harness

4.5 Cable harness

4.5.1 Replacement of cable harness

General
This section describes replacement of complete cable harness.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

CAUTION

Always read the specific instructions for Clean Room robots before doing any
repair work, see Cut the paint or surface on the robot before replacing parts on
page 158.

Continues on next page

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 4 Repair
4.5.1 Replacement of cable harness
Continued

Location

xx0700000562

A R1.MP 1-3
B R1.MP 4-6
C R3.MP2
D R3.MP4
E R3.MP3
F R3.MP1
G R3.FB1
H R3.FB2
I R3.FB3
J R3.FB4
M X1(SMB)
L X2(SMB) - R3.FB1-4

Required equipment and references

Equipment Spare part no. Note

Standard tools Standard toolkit on page 258.

Continues on next page

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4.5.1 Replacement of cable harness
Continued

Equipment Spare part no. Note

Cable harness Spare parts - cable harness.
Cut-off pliers

References
Replacement of base cover gasket on page 160.
Circuit diagram 3HAC028647-009.

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Removal

Action Note
1 Remove the base cover. Described in section Replacement of base cover
gasket on page 160
2 Remove the cable straps holding the
cable harness, using a cut-off pliers.
3 Disconnect all connections.
4 Remove the cable harness.

Refitting

Action Note
1 Refit the new cable harness.
2 Connect all connections. Described in circuit diagram, see Circuit dia-
gram - IRB 360, 3HAC028647-009.
3 Strap all cable connections to there
connector brackets.
4 Refit the base cover. Described in section Replacement of base cover
gasket on page 160.

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 4 Repair
4.5.2 Replacement of brake release button

4.5.2 Replacement of brake release button

Introduction
This section describes replacement of brake release button on the IRB 360.

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Pneumatic or hydraulic related hazards on page 32
• Electrical safety on page 31
• Maintenance and repair on page 34

CAUTION

Always read the specific instructions for Clean Room robots before doing any
repair work, see Cut the paint or surface on the robot before replacing parts on
page 158.

Continues on next page

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4 Repair
4.5.2 Replacement of brake release button
Continued

Location

xx0700000650

A Cover
B Brake release button
C Plastic nut
D Contact
E Locking device

Required equipment

Equipment Spare Part no. Note

Standard tools Standard toolkit on page 258. Spare parts, Brake release
button.

CAUTION

Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 158.

Continues on next page

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 4 Repair
4.5.2 Replacement of brake release button
Continued

Removal

xx0700000644

A Brake release contact

B Cable locking screw
C Locking device

Action Note
1 Remove the base cover. Replacement of base cover gasket on page 160.

CAUTION CAUTION

Clean cover from metal The base cover has sharp edges, use protective
residues before opening. gloves.
Metal residues can cause
shortage on the boards which
can result in hazardous failures.

2 Remove the contact from the

push button, pushing in the Tip
locking device.
Use a screw driver to push in the locking device.

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4 Repair
4.5.2 Replacement of brake release button
Continued

Action Note
3 Loosen the plastic nut and re- Use standard tools.
move the push button from the
transmission cover.

Refitting

Action Note
1 Refit the push button to the
transmission cover using the
plastic nut.
A
Note

Mount the button cover or the

robot will not fulfill the IP67
and IP69K classification.

xx0700000651

2 Press to refit the contact.

xx0800000011

Tip

Refit the cables to the contact before this step.

3 Refit the base cover. Replacement of base cover gasket on page 160

CAUTION

The base cover has sharp edges, use protective gloves.

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 5 Calibration information
5.1 When to calibrate

5 Calibration information
5.1 When to calibrate

When to calibrate
The system must be calibrated if any of the following situations occur.

The resolver values are changed

If resolver values are changed, the robot must be re-calibrated using the calibration
methods supplied by ABB. Calibrate the robot carefully with standard calibration,
according to information in this manual.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.

The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 241. This will occur when:
• The battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are
connected at the first installation.

The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot
is changed, it needs to be re-calibrated for new resolver values.
The resolver values must be updated if the robot is stopped with the emergency
stop or by breaking a safety chain, and after running in to a mechanical stop.

Robot is not floor mounted

The original calibration data delivered with the robot is generated when the robot
is floor mounted. If the robot is not floor mounted, then the robot accuracy could
be affected. The robot needs to be calibrated after it is mounted.

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5 Calibration information
5.2 Calibration method

5.2 Calibration method

Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.

Types of calibration

Type of Description Calibration method

calibration
Standard calibration Standard calibration is performed if resolver Calibration by hand
values are changed or the robot is rebuilt (see with activated brake
When to calibrate on page 227). release, using the calib-
The robot is positioned at calibration position, ration marks.
that is when the positions of the axes 1-3
(angles) are set to parameter values found in
Calibration Position, see type Arm, topic Mo-
tion in Technical reference manual - System
parameters.
Standard calibration data is found on the SMB
(serial measurement board) in the robot.
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Factory reset A factory reset (calibration with a calibration Ring calibration
ring) can be performed after a gearbox or an
upper arm has been replaced to ensure en-
hanced robot arm accuracy than when perform-
ing standard calibration. Factory reset alters
the robot's unique production settings for axis
1-3.
To perform ring calibration, the parallel arms
must first be removed from the robot. The up-
per arms must then be positioned vertically
so that the calibration ring can be fitted to
them.
Making a factory reset with the calibration ring
requires specific calibration equipment and
software, and is performed by ABB. Please
contact ABB.
The parameter Calibration Position (cal_posi-
tion) is set at the ABB factory, and is a robot
specific parameter. For more information about
parameter Calibration Position, see topic Mo-
tion, type Arm in Technical reference manu-
al - System parameters.

Calibration methods
The calibration method for the IRB 360 is different from other robots, and normal
calibration methods are not applicable.

Calibration by hand
Standard calibration is detailed in section Calibrating axis 1-3 on page 232.

Continues on next page

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 5 Calibration information
5.2 Calibration method
Continued

Ring calibration
A factory reset using ring calibration requires specific calibration equipment and
is performed by ABB. Please contact ABB.
Ring calibration is measuring each contact point for axis 1-3 and modifies
cal_position. The Ring calibration method gives a better nominal kinematics and
the modified cal_positions will help to get back to the same points when calibrating
with Standard calibration.

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5 Calibration information
5.3 Calibration movement directions for all axes

5.3 Calibration movement directions for all axes

Overview
When calibrating, the axis must consistently be run towards the calibration position
in the same direction in order to avoid position errors caused by backlash in gears
and so on. Positive directions are shown in the graphic below.

Calibration movement and jogging directions

The following graphic shows the positive and negative directions for each axis and
the linear directions when jogging the robot in the base coordinate system.

+Y
B

-
-

A +X
C
+
+

+Z

- +
D
xx0700000448

A Axis 1
B Axis 2
C Axis 3
D Axis 4

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 5 Calibration information
5.4 Synchronization marks and synchronization position for axes

5.4 Synchronization marks and synchronization position for axes

Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.

Synchronization marks, IRB 360

xx0700000569

A Calibration mark axis 4

B Calibration marks axis 1-3

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5 Calibration information
5.5 Calibrating axis 1-3

5.5 Calibrating axis 1-3

General
This section is valid for IRB 360 all models. It describes how to perform the actual
fine calibration of axis 1-3.
If the robot needs to have a factory reset instead, please contact ABB. See
Calibration method on page 228.
The calibration positions are shown in Checking the synchronization position on
page 245

Note

Calibration should be performed by specially trained personnel.

Axis moving directions

-

+Y
B

-
-

A +X
C
+
+

+Z

- +
D
xx0700000448

A Axis 1
B Axis 2
C Axis 3
D Axis 4

Continues on next page

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 5 Calibration information
5.5 Calibrating axis 1-3
Continued

Calibrating axes 1-3

When connecting to IRC5 controller

Action Note
1 On the FlexPendant, press the stop
button.
2 On the controller, set the key switch
into manual position.

xx0700000625

3 Check the motors off button, make

sure that the button flashes.

en0400000795

4 Press the brake release button to re-

lease the brakes.

xx0700000435

A Brake release button

Continues on next page

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5 Calibration information
5.5 Calibrating axis 1-3
Continued

Action Note
5 Push the upper arm very gently
against the calibration device.

Note

Always calibrate one axis a time,

starting with axis 1.

xx0700000626

A Calibration device
6 When the upper arm reaches the cal- The upper arm is now in calibration position.
ibration device, apply the brake.
7 Store the resolver value by doing a Described in section Fine calibration procedure
fine calibration. on FlexPendant on page 238
8 Release the brakes and gently pull the
calibrated upper arm in to a horizontal
position.
9 Return to step 4, and proceed with
axis 2 and 3.

When connecting to OmniCore controller

Action Note
1 On the FlexPendant, press the stop
button.
2 On the FlexPendant, press Manual to
switch to manual mode.
3 On the FlexPendant, press Motor Off
to set the robot as motor off status.

xx2000002535

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 5 Calibration information
5.5 Calibrating axis 1-3
Continued

Action Note
4 Press the brake release button to re-
lease the brakes.

xx0700000435

A Brake release button

5 Push the upper arm very gently
against the calibration device.

Note

Always calibrate one axis a time,

starting with axis 1.

xx0700000626

A Calibration device
6 When the upper arm reaches the cal- The upper arm is now in calibration position.
ibration device, apply the brake.
7 Store the resolver value by doing a Described in section Fine calibration procedure
fine calibration. on FlexPendant on page 238
8 Release the brakes and gently pull the
calibrated upper arm in to a horizontal
position.
9 Return to step 4, and proceed with
axis 2 and 3.

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5 Calibration information
5.6 Calibrating axis 4

5.6 Calibrating axis 4

General
This section is valid for IRB 360 all models. It describes how to perform the actual
fine calibration of axis 4.
The calibration positions are shown in Checking the synchronization position on
page 245
The axes moving directions are shown in Calibrating axis 1-3 on page 232.

Note

Calibration should be performed by specially trained personnel.

Location
IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600

xx0700000629

A Axis 4 calibration mark

Continues on next page

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 5 Calibration information
5.6 Calibrating axis 4
Continued

IRB 360 - 8/1130, IRB 360 - 6/1600

Calibrating axis 4

Action Note
1 In manual mode, tap Jogging/Jog in the
ABB menu.
2 Tap Motion mode to choose group of
axes to jog.
3 Tap Axis 4-6 to jog axis 4.
4 Jog axis 4 so that the calibration marks See figure in Location on page 236.
are in line.
5 Store the resolver value by doing a fine Described in section Fine calibration proced-
calibration. ure on FlexPendant on page 238.
6 Check the position. Described in section Checking the synchron-
ization position on page 245

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5 Calibration information
5.7 Fine calibration procedure on FlexPendant

5.7 Fine calibration procedure on FlexPendant

Overview
This section describes how to use the FlexPendant when performing a fine
calibration of the robot.

Fine calibration procedure when connecting to IRC5 controller

Use this procedure to fine calibrate using the FlexPendant.
Action
1 On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.
2 Tap to select the mechanical unit and then tap Calib. Parameters.

xx1500001762

3 Tap Fine Calibration....

A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to proceed.
• Tap No to cancel.
4 Select the check-box for the axis to calibrate.
5 Tap Calibrate.
A dialog box is displayed, warning that calibration of the selected axes will be changed,
which cannot be undone:
• Tap Calibrate to proceed.
• Tap Cancel to cancel.
Tapping Calibrate results in briefly displaying a dialog box, announcing that the calib-
ration process has started.
The axis is calibrated and the system returns to the list of available mechanical units.

Continues on next page

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 5 Calibration information
5.7 Fine calibration procedure on FlexPendant
Continued

Performing the fine calibration procedure when connecting to OmniCore controller

Note

If the calibration status is Not calibrated, the fine calibration must be performed
before running the axis calibration procedure.

WARNING

Before starting the calibration procedure, you must jog each axis and bring the
robot to synchronization position and make sure that all the notches are matched.

Action Note
1 On the start screen, tap Calibrate.
2 Select Calibration from the menu.
The Mechanical Units page displays a list of
available mechanical units.

Note

This step is required only if you are not already

in the Mechanical Unit page when you open Cal-
ibrate.

Note

The Mechanical Unit page is displayed only if

there are more than one mechanical unit available.
Otherwise, the calibration summary page for the
available mechanical unit is displayed.

3 Select the unit that needs to be calibrated from

the Mechanical Unit list.
The calibration summary for the selected mechan-
ical unit is displayed.
4 On the right pane tap Calibration Methods.
5 Tap Calibration Parameters.
The calibration parameters are displayed.
6 Tap Fine Calibration.
A dialog box is displayed, urging you to use ex-
ternal equipment to perform the actual calibration.
Make sure all necessary calibration equipment is
fitted for the axis to be calibrated.
A warning that performing fine calibration can
change programmed robot positions is also dis-
played:
• Tap Yes to proceed.
• Tap No to cancel.
7 Select the check-box for the current axis/axes to
be calibrated.

Continues on next page

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5 Calibration information
5.7 Fine calibration procedure on FlexPendant
Continued

Action Note
8 Tap Calibrate.
A dialog box is displayed, warning that calibration
of the selected axes will be changed, which cannot
be undone:
• Tap Calibrate to proceed.
• Tap Cancel to cancel.
Tapping Calibrate results in briefly displaying a
dialog box, announcing that the calibration pro-
cess has started.
The axis is calibrated and the system returns to
the list of available mechanical units.
9 Tap OK.
The fine calibration process is complete.

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 5 Calibration information
5.8 Updating revolution counters

5.8 Updating revolution counters

Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.

Step 1 - Manually moving the manipulator to the synchronization position

Use this procedure to manually move the manipulator to the calibration position.

Note

Calibration should be performed by specially trained personnel.

Action Note
1 Manually move the manipulator to the cal- See Calibrating axis 1-3 on page 232, steps
ibration position for axes 1-3 1 to 6.
2 Manually move the manipulator to the cal- See Calibrating axis 4 on page 236, steps 1
ibration position for axis 4 to 4.
3 Continue with step 2, Step 2 - Updating the
revolution counter with the FlexPendant
on page 241.

Step 2 - Updating the revolution counter with the FlexPendant

When connecting to IRC5 controller
Use this procedure to update the revolution counter with the FlexPendant (IRC5).
Action
1 On the ABB menu, tap Calibration.

xx1500000942

Continues on next page

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5 Calibration information
5.8 Updating revolution counters
Continued

Action
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.

xx1500000943

3 A screen is displayed, tap Rev. Counters.

en0400000771

Continues on next page

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 5 Calibration information
5.8 Updating revolution counters
Continued

Action
4 Tap Update Revolution Counters....
A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
5 Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
6 A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the selected revolution counters and removes the tick from
the list of axes.
7
CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 245.

When connecting to OmniCore controller

Use this procedure to update the revolution counter with the FlexPendant
(OmniCore).
Action
1 On the start screen, tap Calibrate.
2 Select Calibration from the menu.
The Mechanical Units page displays a list of available mechanical units.

Note

This step is required only if you are not already in the Mechanical Unit page when
you open Calibrate.

Note

The Mechanical Unit page is displayed only if there are more than one mechanical
unit available. Otherwise, the calibration summary page for the available mechanical
unit is displayed.

3 Select the mechanical unit for which revolution counter need to be updated.
4 The calibration summary page for the selected mechanical unit is displayed.
Calibration method used at factory for each axis is shown, as well as calibration
method used during last field calibration.
5 Tap Calibration Methods on the right pane.
The calibration options are displayed.
6 Tap Revolution Counters.
7 In the Selection column select the axes for which revolution counters need to be up-
dated.

Continues on next page

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5 Calibration information
5.8 Updating revolution counters
Continued

Action
8 Tap Update.
A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update and a confirmation window is displayed.
9 Tap OK.
The revolution counter for the selected axes is updated.
10
CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 245.

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 5 Calibration information
5.9 Checking the synchronization position

5.9 Checking the synchronization position

Introduction
Check the synchronization position of the robot before beginning any programming
of the robot system. This may be done:
• In manual mode using brake release and move all axis by hand.

Using the jogging window on the FlexPendant

xx0700000627

A Calibration position for axis 1-3.

Note

A position where all three axes are in calibration position at the same time (like
in figure) is not possible. Check or calibrate one axis a time, then set the calibrated
axis horizontal.

Action Note
1 In manual mode, tap Jog- Manual mode described in the section Calibrating axis 1-3
ging/Jog in the ABB on page 232.
menu.

Continues on next page

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5 Calibration information
5.9 Checking the synchronization position
Continued

Action Note
2 Tap Motion mode to se-
lect group of axes to jog.
3 Tap to select the axis to
jog, axis 1, 2, or 3.
4 Press the brake release
button to release the
brakes.

xx0700000435

A Brake release button

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 5 Calibration information
5.9 Checking the synchronization position
Continued

Action Note
5 Push the upper arm very
gently against the calibra-
tion device.

Note

Always check one axis at

a time, starting with axis
1.

xx0700000626

A Calibration device

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5 Calibration information
5.9 Checking the synchronization position
Continued

Action Note
6 Check the position of axis
1 in jogging window and
compare with parameter
Calibration Position.

xx0700000628

xx2000002536

The parameter Calibration Position (cal_position) is set at

the ABB factory, and is a robot specific parameter. For more
information about parameter Calibration Position, see topic
Motion, type Arm in Technical reference manual - System
parameters.
7 The value in the jogging
window should be within
the tolerance ±0.1°, If the
axis position is not ok,
calibrate the axis again,
see Ring calibration on
page 229.
8 If the axis position is ok
return to step 4 and check
axes 2 and 3.

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 6 Decommissioning
6.1 Introduction

6 Decommissioning
6.1 Introduction

Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.

General
All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.

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6 Decommissioning
6.2 Environmental information

6.2 Environmental information

Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).

xx1800000058

Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Aluminium Motor housings, telescopic shafts (standard, WD)
Batteries, Lithium Serial measurement board
Carbon fiber Upper arms, tube bars
Cast iron/nodular iron Gear housings, base box (standard, WD)
Copper Cables, motors
Neodymium Brakes, motors
Oil, grease Gearboxes
Plastic/rubber Cables, connectors, transmission cover, and so on.
Stainless steel Base box (WDS), telescopic shafts (WDS)
Steel Gears, screws, joints, brackets, and so on.

Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.

Continues on next page

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 6 Decommissioning
6.2 Environmental information
Continued

Also note that:

• Spills can form a film on water surfaces causing damage to organisms.
Oxygen transfer could also be impaired.
• Spillage can penetrate the soil causing ground water contamination.

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6 Decommissioning
6.3 Scrapping of robot

6.3 Scrapping of robot

Important when scrapping the robot

DANGER

When a robot is disassembled while being scrapped, it is very important to

remember the following before disassembling starts, in order to prevent injuries:
• Always remove all batteries. If a battery is exposed to heat, for example
from a blow torch, it will explode.
• Always remove all oil/grease in gearboxes. If exposed to heat, for example
from a blow torch, the oil/grease will catch fire.
• When motors are removed from the robot, the robot will collapse if it is not
properly supported before the motor is removed.

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 7 Reference information
7.1 Introduction

7 Reference information
7.1 Introduction

General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

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7 Reference information
7.2 Applicable standards

7.2 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.

General
The product is designed in accordance with ISO 10218-1:2011, Robots for industrial
environments - Safety requirements -Part 1 Robots, and applicable parts in the
normative references, as referred to from ISO 10218-1:2011. In case of deviations
from ISO 10218-1:2011, these are listed in the declaration of incorporation which
is part of the product delivery.

Normative standards, ISO

Standard Description
ISO 9283:1998 Manipulating industrial robots - Performance criteria and related
test methods
ISO 10218-2 Robots and robotic devices - Safety requirements for industrial
robots - Part 2: Robot systems and integration
ISO 12100 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design
ISO 13850 Safety of machinery - Emergency stop - Principles for design
IEC 60204-1:2005 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
IEC 62061:2005 Safety of machinery - Functional safety of safety-related elec-
trical, electronic and programmable electronic control systems

Region specific standards and regulations

Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require-
ments

Other standards used in design

Standard Description
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
(option 129-1) standards – Emission standard for industrial environments

Continues on next page

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 7 Reference information
7.2 Applicable standards
Continued

Standard Description
ISO 13732-1:2008 Ergonomics of the thermal environment - Part 1
IEC 60974-1:2012 i Arc welding equipment - Part 1: Welding power sources
IEC 60974-10:2014 i Arc welding equipment - Part 10: EMC requirements
ISO 14644-1:2015 ii Classification of air cleanliness
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots.
ii Only robots with protection Clean Room.

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7 Reference information
7.3 Unit conversion

7.3 Unit conversion

Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

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 7 Reference information
7.4 Weight specifications

7.4 Weight specifications

Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. All components exceeding 22 kg (50 lbs) are
highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory when handling
components with a weight exceeding 22 kg. A wide range of lifting accessories
and devices are available for each manipulator model.

Example
Following is an example of a weight specification in a procedure:
Action Note

CAUTION

The arm weighs 25 kg.

All lifting accessories used must be sized accord-
ingly.

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7 Reference information
7.5 Standard toolkit

7.5 Standard toolkit

General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.

Contents, standard toolkit

Qty Tool
1 Ring-open-end spanner 7-35mm
1 Socket head cap 3, 5, 8 mm
1 Torque wrench 4-33 Nm
1 Small screwdriver
1 Plastic mallet
1 Ratchet head for torque wrench 1/2
1 Cut-off pliers
1 90° angled bit holder
Spirit level

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 7 Reference information
7.6 Special tools

7.6 Special tools

General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard toolkit on page 258, and of special tools, listed directly in the instructions
and also gathered in this section.

Special tools
The following table specifies the special tools required during service procedures.
The tools are also specified directly in concerned procedures for repair.
Description Art.no. Robot variant
Press tool for bearing 3HAC4184-1 IRB 360 - 1/1130, IRB 360 - 3/1130,
(Drifter for mounting bearing rings.) IRB 360 - 1/800, IRB 360 - 1/1600

Press tool 3HAC4182-1 IRB 360 - 1/1130, IRB 360 - 3/1130,

(Dolly for joint socket when inserting IRB 360 - 1/800, IRB 360 - 1/1600
new bearing rings.)
Pliers for parallel arms 3HAC6194-1 All variants.
Heat gun - -
(Required if the moveable plate is
stainless, see Removal on page 188.)

Note

The stainless version is not available for the IRB 360 used with OmniCore
controllers.

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7 Reference information
7.7 Lifting accessories and lifting instructions

7.7 Lifting accessories and lifting instructions

General
Many repair and maintenance activities require different pieces of lifting accessories,
which are specified in each procedure.
The use of each piece of lifting accessories is not detailed in the activity procedure,
but in the instruction delivered with each piece of lifting accessories.
This implies that the instructions delivered with the lifting accessories should be
stored for later reference.

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 7 Reference information
7.8 Grease specification

7.8 Grease specification

Oil in gearboxes
The types and volumes of oil in the gearboxes are defined in the Technical reference
manual - Lubrication in gearboxes - 3HAC042927-001.
This is detailed in section Type of lubrication in gearboxes on page 125.

Grease in robot

xx0700000725

Pos. For: Type Spare part number Amount

E Telescopic shaft Food accepted FM 222 3HAC042560-001
WDS
F Spring units Food accepted FM 222 3HAC042560-001

Continues on next page

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7 Reference information
7.8 Grease specification
Continued

Grease on sealings

xx0700000706

Pos. For: Type Spare part num- Amount

ber
G O-rings in gear units Food accepted FM 222 3HAC042560-001

Continues on next page

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 7 Reference information
7.8 Grease specification
Continued

xx0800000003

Pos. For: Type Spare part num- Amount

ber
I Grease in swivel Food accepted FM 222 3HAC042560-001

Continues on next page

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7 Reference information
7.8 Grease specification
Continued

xx0800000004

Pos. For: Type Spare part num- Amount

ber
J Grease in ax 4 Food accepted FM 222 3HAC042560-001

Grease on bearing rings

Note

Only lubricate bearing rings 3HAC2091-1. Bearing rings 3HAC028087-001 must

not be lubricated!
Read about the difference in Different versions of bearing rings require different
maintenance procedures on page 104.

Continues on next page

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 7 Reference information
7.8 Grease specification
Continued

Required equipment Article number Note

Grease - Required for non-maintenance
free bearing rings.
• FM 222 (was Mobilgrease
FM 102 or Optimol Obeen
UF 2)
See Different versions of bearing
rings require different mainten-
ance procedures on page 104.

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 8 Spare part lists
8.1 Spare part lists and illustrations

8 Spare part lists

8.1 Spare part lists and illustrations

Location
Spare parts and exploded views are not included in the manual but delivered as
a separate document for registered users on myABB Business Portal,
www.abb.com/myABB.

Tip

All documents can be found via myABB Business Portal, www.abb.com/myABB.

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This page is intentionally left blank
 Index

Index grease, 34
disposal, 250
A H
acids, 141, 143, 145 hanging
allergenic material, 30 installed hanging, 30
aluminum hazard levels, 21
disposal, 250 hazardous material, 250
assembly instructions, 41 height
assessment of hazards and risks, 30 installed at a height, 30
hot surfaces, 34
B HRA, 30
batteries
disposal, 250 I
battery pack installation
replacing, interval, 92 checking site prior robot installation, 43
brake release button instructions for assembly, 41
replacing, 223 integrator responsibility, 30
brakes
testing function, 38 L
labels
C robot, 23
cabinet lock, 31 lifting accessory, 54–55, 257
cabling between robot and controller, 86 lifting eyes, 55
calibrating lifting position, 53
roughly, 241 Lift the robot, 54
calibration limitation of liability, 19
fine calibration, 238 Lithium
rough, 241 disposal, 250
standard type, 228 loads, 72
when to calibrate, 227 lock and tag, 31
calibration marks, 231 lubricants, 34
calibration position lubrication
scales, 231 amount in gearboxes, 125
calibration scales, 231 type of lubrication, 125
carbon dioxide extinguisher, 31
carbon fiber M
disposal, 250 manipulator cables
cast iron customer cables, 86
disposal, 250 power cables, 86
check, installation site, 43 signal cables, 86
cleaning, 136 Movable Plate, 178
climbing on robot, 34
Cold environments, 88 N
connecting the robot and controller, cabling, 86 national regulations, 30
copper negative directions, axes, 230
disposal, 250 neodymium
Customer connections, 77 disposal, 250
nodular iron
D disposal, 250
detergents, 141, 143, 145
direction of axes, 230 O
oil, 34
E amount in gearboxes, 125
environmental information, 250 disposal, 250
ESD type of oil, 125
damage elimination, 52 original spare parts, 19
sensitive equipment, 52
P
F pedestal
fire extinguishing, 31 installed on pedestal, 30
Fitting equipment, 66 personnel
FlexPendant requirements, 20
updating revolution counters, 241 plastic
disposal, 250
G positive directions, axes, 230
gearboxes PPE, 20
location of, 125

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Index

product standards, 254 replacing, 163

protective equipment, 20 space required, 57
protective wear, 20 special tools, 259
speed
R adjusting, 88
regional regulations, 30 stainless steel
release brakes, 37 disposal, 250
replacements, report, 149 standards, 254
report replacements, 149 ANSI, 254
required space, 57 CAN, 254
responsibility and validity, 19 EN IEC, 254
revolution counters EN ISO, 254
storing on FlexPendant, 241 start of robot in cold environments, 88
updating, 241 steel
risk of burns, 34 disposal, 250
robot symbols
labels, 23 safety, 21
symbols, 23 synchronization position, 241
roundslings, 55 sync marks, 231
rubber system integrator requirements, 30
disposal, 250
T
S testing
safety brakes, 38
brake testing, 38 tools
ESD, 52 for service, 259
fire extinguishing, 31 Transport position, 47
release robot axes, 37 troubleshooting
signals, 21 safety, 39
signals in manual, 21
symbols, 21 U
symbols on robot, 23 updating revolution counters, 241
safety devices, 31 users
safety hazard requirements, 20
hydraulic system, 32
pneumatic system, 32 V
Safety lamp, 74 Vacuum System, 81
safety signals validity and responsibility, 19
in manual, 21 velocity
safety standards, 254 adjusting, 88
scales on robot, 231
screw joints, 155 W
secured robot frame, 58 washing, 136
Secure the robot, 60
signals Z
safety, 21 zero position
SMB, 119 checking, 245

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ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400

ABB AS
Robotics & Discrete Automation
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics & Discrete Automation
No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

ABB Inc.
Robotics & Discrete Automation
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000

abb.com/robotics
3HAC030005-001, Rev Z, en

© Copyright 2008-2021 ABB. All rights reserved.

Specifications subject to change without notice.