ROBOTICS

Product manual
IRB 910SC
Trace back information:
Workspace 21C version a3
Checked in 2021-09-23
Skribenta version 5.4.005
 Product manual
IRB 910SC-3/0.45
IRB 910SC-3/0.55
IRB 910SC-3/0.65
IRC5

Document ID: 3HAC056430-001

Revision: M

© Copyright 2016-2021 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 2016-2021 ABB. All rights reserved.

Specifications subject to change without notice.
 Table of contents

Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 13
How to read the product manual ...................................................................................................... 15

1 Safety 17
1.1 Safety information ............................................................................................. 17
1.1.1 Limitation of liability ................................................................................. 17
1.1.2 Requirements on personnel ...................................................................... 18
1.2 Safety signals and symbols ................................................................................. 19
1.2.1 Safety signals in the manual ...................................................................... 19
1.2.2 Safety symbols on manipulator labels ......................................................... 21
1.3 Robot stopping functions .................................................................................... 27
1.4 Installation and commissioning ............................................................................ 28
1.5 Operation ........................................................................................................ 31
1.5.1 Unexpected movement of robot arm ........................................................... 31
1.6 Maintenance and repair ...................................................................................... 32
1.6.1 Maintenance and repair ............................................................................ 32
1.6.2 Emergency release of the robot axes .......................................................... 35
1.6.3 Brake testing .......................................................................................... 36
1.7 Troubleshooting ................................................................................................ 37
1.8 Decommissioning .............................................................................................. 38

2 Installation and commissioning 39

2.1 Introduction to installation and commissioning ....................................................... 39
2.2 Unpacking ....................................................................................................... 40
2.2.1 Pre-installation procedure ......................................................................... 40
2.2.2 Dimensions ............................................................................................ 44
2.2.3 Working range ........................................................................................ 46
2.2.4 Risk of tipping/stability ............................................................................. 50
2.2.5 The unit is sensitive to ESD ....................................................................... 52
2.3 On-site installation ............................................................................................ 53
2.3.1 Lifting robot with lifting accessories ............................................................ 53
2.3.2 Manually releasing the brakes ................................................................... 61
2.3.3 Orienting and securing the robot ................................................................ 63
2.3.4 Loads fitted to the robot, stopping time and braking distances ......................... 65
2.3.5 Fitting equipment on the robot ................................................................... 66
2.4 Restricting the working range .............................................................................. 68
2.4.1 Axes with restricted working range ............................................................. 68
2.4.2 Mechanically restricting the working range ................................................... 69
2.5 Electrical connections ........................................................................................ 71
2.5.1 Robot cabling and connection points .......................................................... 71
2.5.2 Customer connections ............................................................................. 73
2.6 Start of robot in cold environments ...................................................................... 75

3 Maintenance 77
3.1 Introduction ...................................................................................................... 77
3.2 Service Information System (SIS) ......................................................................... 78
3.3 Maintenance schedule ....................................................................................... 79
3.3.1 Specification of maintenance intervals ........................................................ 79
3.3.2 Maintenance schedule ............................................................................. 80
3.4 Inspection activities ........................................................................................... 82
3.4.1 Inspecting the cabling .............................................................................. 82
3.4.2 Inspecting the information labels ................................................................ 83
3.4.3 Inspecting the ball screw spline unit ........................................................... 86
3.4.4 Inspecting axis-1 and axis-2 mechanical stops .............................................. 89
3.4.5 Inspecting the timing belts ........................................................................ 92

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Table of contents

3.5 Replacement/changing activities .......................................................................... 100

3.5.1 Replacing the battery pack ........................................................................ 100
3.6 Lubrication activities .......................................................................................... 111
3.6.1 Lubricating the ball screw spline unit .......................................................... 111
3.7 Cleaning activities ............................................................................................. 114
3.7.1 Cleaning the IRB 910SC ........................................................................... 114

4 Repair 117
4.1 Introduction ...................................................................................................... 117
4.2 General procedures ........................................................................................... 118
4.2.1 Cut the paint or surface on the robot before replacing parts ............................ 118
4.2.2 Mounting instructions for sealings .............................................................. 119
4.3 Cable harness .................................................................................................. 122
4.3.1 Replacing the main cable package ............................................................. 122
4.3.2 Replacing the EIB unit .............................................................................. 146
4.3.3 Replacing the PCB board .......................................................................... 156
4.3.4 Replacing the EIB mounting plate ............................................................... 164
4.3.5 Replacing the floor cables ......................................................................... 183
4.3.6 Replacing the brake release harness .......................................................... 191
4.4 Upper arm ....................................................................................................... 196
4.4.1 Replacing the upper arm .......................................................................... 196
4.4.2 Replacing the ball screw spline unit ............................................................ 229
4.4.3 Replacing the axis-3 timing belt ................................................................. 246
4.4.4 Replacing the axis-4 timing belts ................................................................ 256
4.4.5 Replacing the axis-2 mechanical stop ......................................................... 271
4.5 Lower arm and base .......................................................................................... 276
4.5.1 Replacing the lower arm ........................................................................... 276
4.5.2 Replacing the base ................................................................................. 285
4.5.3 Replacing the axis-1 mechanical stop ......................................................... 296
4.6 Drive units ....................................................................................................... 299
4.6.1 Replacing the axis-1 drive unit .................................................................. 299
4.6.2 Replacing the axis-2 drive unit .................................................................. 308
4.6.3 Replacing the axis-3 drive unit ................................................................... 319
4.6.4 Replacing the axis-4 drive unit ................................................................... 333

5 Calibration 345
5.1 Introduction to calibration ................................................................................... 345
5.1.1 Introduction and calibration terminology ...................................................... 345
5.1.2 Calibration methods ................................................................................. 346
5.1.3 When to calibrate ................................................................................... 348
5.2 Synchronization marks and axis movement directions ............................................. 349
5.2.1 Synchronization marks and synchronization position for axes ......................... 349
5.2.2 Calibration movement directions for all axes ................................................ 350
5.3 Updating revolution counters ............................................................................... 351
5.4 Calibrating the robot .......................................................................................... 355
5.4.1 Calibration position .................................................................................. 355
5.4.2 Calibrating axis 1 .................................................................................... 356
5.4.3 Calibrating axis 2 .................................................................................... 361
5.4.4 Calibrating axis 3 and axis 4 ...................................................................... 366
5.5 Verifying the calibration ...................................................................................... 372
5.6 Checking the synchronization position .................................................................. 373

6 Decommissioning 375
6.1 Introduction ...................................................................................................... 375
6.2 Environmental information .................................................................................. 376

7 Reference information 377

7.1 Introduction ...................................................................................................... 377

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7.2 Applicable standards ......................................................................................... 378

7.3 Unit conversion ................................................................................................. 380
7.4 Specification of screws ....................................................................................... 381
7.5 Screw joints .................................................................................................... 382
7.6 Weight specifications ......................................................................................... 385
7.7 Standard toolkit ................................................................................................ 386
7.8 Special tools .................................................................................................... 387
7.9 Lifting accessories and lifting instructions .............................................................. 389

8 Spare parts 391

8.1 Spare part lists and illustrations ........................................................................... 391

9 Circuit diagrams 393

9.1 Circuit diagrams ................................................................................................ 393

Index 395

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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 robot
• maintenance of the robot
• mechanical and electrical repair of the robot.

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

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.

Product manual scope

The manual covers covers all variants and designs of the IRB 910SC. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.

Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety, service Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information on how to avoid
personal injuries and damage to the product.
Installation and commis- Required information about lifting and installation of the robot.
sioning
Maintenance Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.

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Continued

Chapter Contents
Calibration information Procedures that do not require specific calibration equipment.
General information about calibration.
Decommissioning Environmental information about the robot and its components.
Reference information Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards, etc.
Spare parts and exploded Reference to the spare part list for the robot.
views
Circuit diagram Reference to the circuit diagram for the robot.

References
Documentation referred to in the manual, is listed in the table below.
Document name Document ID
Product manual, spare parts - IRB 910SC 3HAC056433-001
Product specification - IRB 910SC 3HAC056431-001
Circuit diagram - IRB 910SC 3HAC056159-002
Product manual - IRC5 Compact 3HAC047138-001
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Technical reference manual - Lubrication in gearboxes 3HAC042927-001
Technical reference manual - System parameters 3HAC050948-001
Operating manual - Emergency safety information 3HAC027098-001
Safety manual for robot - Manipulator and IRC5 or OmniCore con- 3HAC031045-001
troller i
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.

Revisions

Revision Description
- First edition.

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Continued

Revision Description
A The following updates are done in this revision:
• Working range of axis 4 has been updated. See Working range
on page 48.
• The force and torque values under endurance load and maximum
load have been updated. See Loads on foundation, robot on
page 41.
• The interval of lubricating the ball screw spline unit is modified to
every 100 km. See Activities and intervals, standard equipment
on page 80.
• The grease for lubrication the ball screw spline unit is changed
from AFB-LF to AFA. See "Required consumables" in Lubricating
the ball screw spline unit on page 111 and Replacing the ball screw
spline unit on page 229.
• The spare part numbers of base and lifting labels have been
changed.
• The instruction label of lifting the robot has been changed. See
Location of labels on page 83.
• Washers and locking liquid Loctite 243 are used when refitting
the base rear cover and floor cables, and at the same time, the
tightening torque of related screws changes from 4.5 Nm to 2 Nm.
• The tightening torque of the screws on base bottom cover is ad-
ded, which is 2 Nm.
• A caution reminding not to mix axis-1 and axis-2 drive units has
been added in procedures of refitting the drive units.
• Screws for fitting the calibration pins of axes 1 and 2 have been
removed. See Calibrating axis 1 on page 357 and Calibrating axis
2 on page 362.
B • Information about customer connectors has been added. See
Customer connections on page 73.
• Dimension drawing for fitting the end effector is updated. See
Fitting of end effector to the ball screw spline shaft on page 66.
• Information about the grease used for lubricating the ball screw
spline is updated.
• Locking liquid Loctite 243 is not required when refitting the base
rear cover and floor cables.
• Calibration tools are not provided as a package so that the calib-
ration toolkit is removed.
• Fixing calibration block of axes 3 and 4 is fixed to the upper arm
so that related repairing procedures are removed.
• Minor corrections.
C Published in release R17.1. The following updates are done in this revi-
sion:
• The spare part number of the lower cover of the upper arm is
changed from 3HAC055203-001 to 3HAC060106-001.
• Upper and lower axis-3 and axis-4 stop blocks on the ball screw
spline unit are added as spare parts.
• Unnecessary screws on the lower cover of the upper arm are re-
moved so that related figures are updated.
• Every 100 miles column in Maintenance schedule is removed, the
maintenance interval of inspecting the timing belt is updated
• The Protection class is changed from IP30 to IP20.

Continues on next page

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Continued

Revision Description
D Published in release R17.2. The following updates are made in this revi-
sion:
• Information about coupled axes in Updating revolution counters
on page 351.
• Caution about removing metal residues added in sections about
SMB/EIB boards.
• Information about minimum resonance frequency added.
• Updated list of applicable standards.
• Added text regarding overhaul in section specification of mainten-
ance intervals.
• Section Start of robot in cold environments on page 75 added.
E Published in release R18.1. The following updates are made in this revi-
sion:
• Added sections in General procedures on page 118.
• Safety restructured.
• Added information about SIS function for ball screw spline unit in
Troubleshooting on page 78.
• Information about myABB Business Portal added.
F Published in release R18.2. The following updates are made in this revi-
sion:
• Added equipment fitting note and updated the end effector dimen-
sion figure.
• Moved the robot dimension information to section Unpacking on
page 40.
• Added customer connector information.
• Added replacement of brake release harness.
• Changed timing belt tension of axis 3 and axis 4.
G Published in release R18.2. The following updates are made in this revi-
sion:
• Updated references.
H 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 118.
• Corrected customer connector at the upper arm from R4.CP/CS
to R3.CP/CS.
J Published in release 20A. The following updates are made in this revision:
• Clarified and added information in mounting instructions for rotat-
ing sealings, see Mounting instructions for sealings on page 119.
• Added AbsAcc label information. See Inspecting the information
labels on page 83.
K Published in release 20D. The following updates are made in this revision:
• Option 610-1 Independent axis is removed so that description
about maximum revolution of axis 4 is removed.
L Published in release 21B. The following updates are done in this revision:
• Text regarding fastener quality is updated, see Fastener quality
on page 67.
• Text regarding diameter of air hoses is updated, see Customer
connections on page 73.
• Added grounding point information, see Robot cabling and con-
nection points on page 71.
M Published in release 21C. The following updates are done in this revision:
• Updated the naming of timing belt tension adjustment tools, from
acoustic tensiometer and tensiometer to sonic tension meter and
dynamometer, respectively.
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Continued

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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Product documentation
Continued

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

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 How to read the product manual

How to read the product manual

Reading the procedures
The procedures contain all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.

Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.

Illustrations
The product is illustrated with general figures that does not take painting or
protection type in consideration.
Likewise, certain work methods or general information that is valid for several
product models, can be illustrated with illustrations that show a different product
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 instructions.

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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.
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.

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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 21.
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

Continues on next page

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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 - IRC5 Compact

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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 a risk assessment.

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

Securing the robot to the foundation

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

Electrical safety
The mains power must be installed to fulfill national regulations.

Continues on next page

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 1 Safety
1.4 Installation and commissioning
Continued

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
End-effector hazards require particular attention for applications which involve
close human collaboration with the robot.

Continues on next page

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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, and touching these may result in burns.
Allow the surfaces to cool down before maintenance or repair.

Allergic reaction

Warning Description Elimination/Action

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are 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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1.6.1 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.
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.
There is a hazard in case of abuse (mechanical, thermal, electrical) which leads
to the activation of safety valves and/or the rupture of the battery container. As a
result under certain circumstances, electrolyte leakage, electrode materials reaction
with moisture/water or battery vent/explosion/fire may follow.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Operating conditions, robot on page 43.
See safety instructions for the batteries in Material/product safety data
sheet - Battery pack (3HAC043118-001).
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1 Safety
1.6.1 Maintenance and repair
Continued

Unexpected movement of robot arm

WARNING

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

WARNING

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

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

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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 61.
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

It is recommended to run the service routine BrakeCheck as part of the regular

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

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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 375.

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
910SC at the working site.
See also the product manual for the robot controller.
The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.

Safety information
Before any installation work is commenced, all safety information must be observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 17 before performing any installation
work.

Note

Always connect the IRB 910SC and the robot to protective earth and residual
current device (RCD) before connecting to power and starting any installation
work.
For more information see:
• Product manual - IRC5 Compact

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2 Installation and commissioning
2.2.1 Pre-installation procedure

2.2 Unpacking

2.2.1 Pre-installation procedure

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

Prerequisites for installation personnel

Installation personnel working with an ABB product must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/maintenance/repair work
• conform to all national and local codes.

Checking the pre-requisites for installation

Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.

Note

Stop unpacking and contact ABB if transport damages are found.

4 Clean the unit with a lint-free cloth, if necessary.

5 Make sure that the lifting accessory used (if required) is suitable to handle the weight
of the robot as specified in: Weight, robot on page 41
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 42
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 43
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 41
• Protection classes, robot on page 43
• Requirements, foundation on page 42
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 50
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 53
11 Install required equipment, if any.

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 2 Installation and commissioning
2.2.1 Pre-installation procedure
Continued

Weight, robot
The table shows the weight of the robot.
Robot model Weight
IRB 910SC IRB 910SC-3/0.45: 24.5 kg
IRB 910SC-3/0.55: 25 kg
IRB 910SC-3/0.65: 25.5 kg

Note

The weight does not include tools and other equipment fitted on the robot.

Loads on foundation, robot

The illustration shows the directions of the robots stress forces.

xx1500002522

Fxy Force in any direction in the XY plane

Fz Force in the Z plane
Txy Bending torque in any direction in the XY plane
Tz Bending torque in the Z plane

The table shows the various forces and torques working on the robot during different
kinds of operation.

Note

These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!

Continues on next page

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2.2.1 Pre-installation procedure
Continued

WARNING

The robot installation is restricted to the mounting options given in following load
table(s).

Floor mounted

Force Endurance load (in operation) Max. load (emergency stop)

Force xy ±651 N ±945 N
Force z 255±392 N 255±441 N
Torque xy ±260 Nm ±418 Nm
Torque z ±121 Nm ±238 Nm

Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.1/500 mm Flat foundations give better repeatability of the
surface resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
In order to compensate for an uneven surface,
the robot can be recalibrated during installation.
If resolver/encoder calibration is changed this
will influence the absolute accuracy.
Maximum tilt 0°
Minimum resonance 22 Hz The value is recommended for optimal perform-
frequency ance.
Note Due to foundation stiffness, consider robot mass
including equipment. i
It may affect the For information about compensating for founda-
manipulator life- tion flexibility, see Application manual - Control-
time to have a ler software IRC5, section Motion Process Mode.
lower resonance
frequency than
recommended.

i The minimum resonance frequency given should be interpreted as the frequency of the robot
mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e.,
the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should
not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent
mass of the floor is very high, it will not affect robot movement, even if the frequency is well below
the stated frequency. The robot should be mounted as rigid as possibly to the floor.
Disturbances from other machinery will affect the robot and the tool accuracy. The robot has
resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified,
although somewhat damped by the servo control. This might be a problem, depending on the
requirements from the applications. If this is a problem, the robot needs to be isolated from the
environment.

Storage conditions, robot

The table shows the allowed storage conditions for the robot:
Parameter Value
Minimum ambient temperature -25°C
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2.2.1 Pre-installation procedure
Continued

Parameter Value
Maximum ambient temperature 55°C
Maximum ambient temperature (less than 24 hrs) 70°C
Maximum ambient humidity 95% at constant temperature
(gaseous only)

Operating conditions, robot

The table shows the allowed operating conditions for the robot:
Parameter Value
Minimum ambient temperature 5°C i
Maximum ambient temperature 45°C
Maximum ambient humidity 95% at constant temperature
i At low environmental temperature < 10°C is, as with any other machine, a warm-up phase
recommended to be run with the robot. Otherwise there is a risk that the robot stops or run with
lower performance due to temperature dependent oil and grease viscosity.

Protection classes, robot

The table shows the available protection types of the robot, with the corresponding
protection class.
Protection type Protection class
Manipulator, protection type Standard IP20

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2 Installation and commissioning
2.2.2 Dimensions

2.2.2 Dimensions

Dimensions IRB 910SC

The figure shows the dimension of the robot.

xx1500002526

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 2 Installation and commissioning
2.2.2 Dimensions
Continued

Item Description Variant

IRB 910SC- IRB 910SC- IRB 910SC-
3/0.45 3/0.55 3/0.65
L Length of lower arm 200 mm 300 mm 400 mm
A Maximum height 620 mm 620 mm 620 mm
B Z stroke 180 mm 180 mm 180 mm

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2 Installation and commissioning
2.2.3 Working range

2.2.3 Working range

Illustration, working range and turning radius IRB 910SC-3/0.45

This illustration shows the unrestricted working range and turning radius of IRB
910SC-3/0.45.

(b)
(a)

A A

C
H C
G
E
D F
D

J
K
B B

Q N

(d) (c)
xx1500002474

a Maximum space F 119 mm

b Center joint of axis 3 G 200 mm
c Base mounting face H 450 mm
d Area limited by mechanical stop J 150°
A 140° K 151.2°
B 1.5° M 180 mm
C 150° N 5 mm
D 1.2° P 2 mm

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 2 Installation and commissioning
2.2.3 Working range
Continued

E 126 mm Q 40.2 mm

Illustration, working range and turning radius IRB 910SC-3/0.55

This illustration shows the unrestricted working range and turning radius of IRB
910SC-3/0.55.
(a) (b)

A A

H C C

G
D D

E
F

J
K
B B

N
Q

(d) (c)
xx1500002475

a Maximum space F 145 mm

b Center joint of axis 3 G 300 mm
c Base mounting face H 550 mm
d Area limited by mechanical stop J 150°
A 140° K 151.2°
B 1.5° M 180 mm
C 150° N 5 mm
D 1.2° P 2 mm
E 150 mm Q 40.2 mm

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2 Installation and commissioning
2.2.3 Working range
Continued

Illustration, working range and turning radius IRB 910SC-3/0.65

This illustration shows the unrestricted working range and turning radius of IRB
910SC-3/0.65.
(a) (b)

A A

H C C

D D
G

E
F

B B
P

Q N

(c)
(d)
xx1500002476

a Maximum space F 217 mm

b Center joint of axis 3 G 400 mm
c Base mounting face H 650 mm
d Area limited by mechanical stop J 150°
A 140° K 151.2°
B 1.5° M 180 mm
C 150° N 5 mm
D 1.2° P 2 mm
E 222 mm Q 40.2 mm

Working range

Axis Type of motion Working range

Axis 1 Rotation motion -140° to +140°

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2.2.3 Working range
Continued

Axis Type of motion Working range

Axis 2 Rotation motion -150° to +150° i
Axis 3 Linear motion -180 mm to 0 mm
Axis 4 Rotation motion Default: -400° to +400° ii
i The axis 2 can be restricted to a smaller working range by fitting one more axis-2 mechanical stop
block to the upper arm. For how to fit the block, see Replacing the axis-2 mechanical stop block
on page 272.
The additional mechanical stop block and related screws are provided in accessory package.
ii The default working range for axis 4 can be extended by changing parameter values in the software.

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2 Installation and commissioning
2.2.4 Risk of tipping/stability

2.2.4 Risk of tipping/stability

Risk of tipping
Do not change the robot position before securing it to the foundation.
The shipping position is the most stable position.

Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.

IRB 910SC-3/0.45

xx1500002487

IRB 910SC-3/0.55 and IRB 910SC-3/0.65

xx1500002492

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2.2.4 Risk of tipping/stability
Continued

WARNING

The robot will be mechanically unstable if not properly secured to the foundation.

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2 Installation and commissioning
2.2.5 The unit is sensitive to ESD

2.2.5 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 Installation and commissioning
2.3.1 Lifting robot with lifting accessories

2.3 On-site installation

2.3.1 Lifting robot with lifting accessories

Introduction
IRB 910SC-3/0.45

xx1500002472

IRB 910SC-3/0.55 and IRB 910SC-3/0.65

xx1500002473

Required equipment

Equipment Article number Note

Overhead crane -

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2 Installation and commissioning
2.3.1 Lifting robot with lifting accessories
Continued

Equipment Article number Note

Lifting chain - > 50 kg (capacity of lifting chain)
Hook -
Lifting accessory, robot - Includes lifting accessories and
screws.

Lifting the robot

Use this procedure to lift the robot.
Action Note
1 Move the robot to the appropriate lifting posi- Valid for IRB 910SC-3/0.45
tion.

WARNING

The robot is likely to be mechanically unstable

if not secured to the foundation!

xx1500002483

Valid for IRB 910SC-3/0.55 and IRB

910SC-3/0.65

xx1500002488

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 2 Installation and commissioning
2.3.1 Lifting robot with lifting accessories
Continued

Action Note
2 Fold the lifting paper box to the required shape Valid for IRB 910SC-3/0.45
and put it to the proper position under the lower
arm.

xx1500002484

Valid for IRB 910SC-3/0.55 and IRB

xx1500002493
910SC-3/0.65

Note

For the IRB 910SC-3/0.45, fold the part pointing

out in the figure along the folding mark so that
a space will be left for the axis-1 mechanical
stop block.

xx1500002489

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2 Installation and commissioning
2.3.1 Lifting robot with lifting accessories
Continued

Action Note
3 Fit the lifting bracket. Valid for IRB 910SC-3/0.45

xx1500002485

Valid for IRB 910SC-3/0.55 and IRB

910SC-3/0.65

xx1500002490

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 2 Installation and commissioning
2.3.1 Lifting robot with lifting accessories
Continued

Action Note
4 Insert the metal plate through the bracket and Valid for IRB 910SC-3/0.45
the paper box.

Note

IRB 910SC-3/0.45: Use lower lug on the

bracket.
IRB 910SC-3/0.55 and IRB 910SC-3/0.65: Use
upper lug on the bracket.

xx1500002771

Valid for IRB 910SC-3/0.55 and IRB

910SC-3/0.65

xx1500002772

Continues on next page

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2 Installation and commissioning
2.3.1 Lifting robot with lifting accessories
Continued

Action Note
5 Secure the metal plate with screw(s). Valid for IRB 910SC-3/0.45
IRB 910SC-3/0.45: One screw at each side.
IRB 910SC-3/0.55 and IRB 910SC-3/0.65: One
screw at one side only.

xx1500002486

Screw: M4x30 (2 pcs)

Tightening torque: 0.3-0.4 Nm
Valid for IRB 910SC-3/0.55 and IRB
910SC-3/0.65

xx1500003067

Screw: M4x12 (1 pcs)

Tightening torque: 0.2-0.3 Nm
6 For IRB 910SC-3/0.55 and IRB 910SC-3/0.65 Screw: M4x12 (4 pcs)
Fasten two screws at each side to clamp the Tightening torque: 0.2-0.3 Nm
metal plate and the bracket.

xx1500002491

7
CAUTION

The IRB 910SC robot weighs 25.5 kg at a

maximum.
All lifting accessories used must be sized ac-
cordingly!

8
WARNING

Personnel must not, under any circumstances,

be present under the suspended load!

Continues on next page

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 2 Installation and commissioning
2.3.1 Lifting robot with lifting accessories
Continued

Action Note
9 Attach the lifting chain to the robot. Lifting capacity for the lifting chain is
specified in Required equipment on
page 53.
Valid for IRB 910SC-3/0.45

xx1500002495

Valid for IRB 910SC-3/0.55 and IRB

910SC-3/0.65

xx1500002494

10 Carefully stretch the chain by lifting the crane

slowly.
This prevents the robot from falling down when
it is unfastened or the support is removed. Do
not overstretch the chain if the robot is
fastened because there is a risk of the robot
being damaged.
11 Remove the robot attachment screws (if the Screw: M10x25 (4 pcs)
robot is fastened).

xx1500002773

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2 Installation and commissioning
2.3.1 Lifting robot with lifting accessories
Continued

Action Note
12 Raise the overhead crane to lift the robot.

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 2 Installation and commissioning
2.3.2 Manually releasing the brakes

2.3.2 Manually releasing the brakes

Introduction to manually releasing the brakes

This section describes how to release the holding brakes for the motors of each
axis.

Location of brake release unit

The internal brake release unit is located as shown in the figure.

xx1500002173

Releasing the brakes

This procedure details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
Action Note
1 The internal brake release unit is equipped with a
button for controlling the axes brakes.
If the robot is not connected to the controller,
power must be supplied to the connector R1.MP
according to the section Supplying power to con-
nector R1.MP on page 62.

xx1500002774

Continues on next page

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2 Installation and commissioning
2.3.2 Manually releasing the brakes
Continued

Action Note
2
DANGER

When releasing the holding brakes, the robot axes

may move very quickly and sometimes in unexpec-
ted ways!
Make sure the payload is disassembled or tooling
is properly supported; otherwise, fast downward
movements of axis 3 may cause severe hits.

3 Release the holding brake on all robot axes by

pressing the button on the internal brake release
unit.
The brake will function again as soon as the button
is released.

Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector
R1.MP on the robot in order to enable the brake release buttons.
Action Note
1
DANGER

Incorrect connections, such as supplying

power to the wrong pin, may cause all
brakes to be released simultaneously!

2 Supply +24V on pin 15 and 0V on pin 8.

Note

Do not interchange the 24V and 0V pins.

If they are mixed up, damage can be
caused to the brake release unit and to the
system board.

xx1500002477

A R1.MP

xx1500002478

A 0V (8)
B +24V (15)

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 2 Installation and commissioning
2.3.3 Orienting and securing the robot

2.3.3 Orienting and securing the robot

Introduction
This section details how to orient and secure the robot to the foundation or base
plate in order to run the robot safely. The requirements made on the foundation
are shown in sections:
• Loads on foundation, robot on page 41
• Requirements, foundation on page 42.

Hole configuration, base

The illustration shows the hole configuration used when securing the robot.

xx1500002521

Specification, attachment screws and pins

The table specifies the type of securing screws and washers to be used to secure
the robot directly to the foundation. It also specifies the type of pins to be used.
Suitable screws M10x25
Quantity 4 pcs
Quality 8.8
Suitable washer 20x10.5x2
Guide pins 2 pcs, D6x20, ISO 2338 - 6m6x20 - A1
Tightening torque 45 Nm
Level surface requirements

0.1

xx1500000627

Continues on next page

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2 Installation and commissioning
2.3.3 Orienting and securing the robot
Continued

Orienting and securing the robot

Use this procedure to orient and secure the robot.
Action Information
1 Make sure the installation site for the robot con-
forms to the specifications in section:
• Pre-installation procedure on page 40.
2 Prepare the installation site with attachment The hole configuration of the base
holes. is shown in the figure in Hole config-
uration, base on page 63.
3
CAUTION

The IRB 910SC robot weighs 25.5 kg at a maxim-

um.
All lifting accessories used must be sized accord-
ingly!

4
CAUTION

When the robot is put down after being lifted or

transported, there is a risk of it tipping, if not
properly secured.

5 Lift the robot to its installation site. See Lifting robot with lifting accessor-
ies on page 53.
6 Fit two pins to the holes in the base. 2 pcs, D6x20, ISO 2338 - 6m6x20 -
A1
7 Guide the robot gently, using the attachment Make sure the robot base is cor-
screws while lowering it into its mounting posi- rectly fitted onto the pins.
tion.
8 Fit the securing screws and washers in the attach- Screws: M10x25, quality: 8.8
ment holes of the base.
9 Tighten the bolts in a criss-cross pattern to en- Tightening torque:
sure that the base is not distorted. 45 Nm

Securing robot on a mounting plate

When bolting a mounting plate or frame to a concrete floor, follow the general
instructions for expansion-shell bolts.
Screw joints must be able to withstand the stress loads defined in section Loads
on foundation, robot on page 41.

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 2 Installation and commissioning
2.3.4 Loads fitted to the robot, stopping time and braking distances

2.3.4 Loads fitted to the robot, stopping time and braking distances

General
Any loads mounted on the robot must be defined correctly and carefully (with
regard to the position of center of gravity and mass moments of inertia) in order
to avoid jolting movements and overloading motors, gears and structure.

CAUTION

Incorrectly defined loads may result in operational stops or major damage to the
robot.

References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must be defined in the software.
• Operating manual - IRC5 with FlexPendant

Stopping time and braking distances

The performance of the motor brake depends on if there are any loads attached
to the robot. For more information, see product specification for the robot.

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2 Installation and commissioning
2.3.5 Fitting equipment on the robot

2.3.5 Fitting equipment on the robot

Fitting of end effector to the ball screw spline shaft

An end effector can be attached to the lower end of the shaft of the ball screw
spline unit. The dimensions for fitting the end effector is shown in the following
figure.

Note

Mounting of other equipment on the IRB 910SC may damage the gearboxes.

40
7.50

10

20 h7
10
10

xx1700001187

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 2 Installation and commissioning
2.3.5 Fitting equipment on the robot
Continued

14 (D)
E A

xx1500002523

A Flat cut
B Conical hole
C Stop block diameter
D Through hole
E Shaft diameter

Fastener quality
When fitting tools on the tool flange, only use screws with quality 12.9. For other
equipment use suitable screws and tightening torque for your application.

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2 Installation and commissioning
2.4.1 Axes with restricted working range

2.4 Restricting the working range

2.4.1 Axes with restricted working range

General
When installing the robot, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space
should be limited.
The working range of the following axes may be restricted:
• Axis 1, hardware (mechanical stop)
• Axis 2, hardware (mechanical stop)
• Axes 3 and 4, hardware (stop block)
This section describes how to install hardware that restricts the working range.

Note

Adjustments must also be made in the robot configuration software (system

parameters). References to relevant manuals are included in the installation
procedures.

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 2 Installation and commissioning
2.4.2 Mechanically restricting the working range

2.4.2 Mechanically restricting the working range

Location of mechanical stops

The figures shows where the mechanical stops are placed on the robot.

xx1500002811

A Mechanical stop block, axis 1 (lower arm)

B Mechanical stop block, axis 2 (upper arm)

xx1500002814

A Mechanical stop rubbers, axis 1 (base)

B Mechanical stop rubbers, axis 2 (lower arm)

Continues on next page

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2 Installation and commissioning
2.4.2 Mechanically restricting the working range
Continued

xx1500002813

A Upper stop block, axes 3 and 4 (upper arm)

B Lower stop block, axes 3 and 4 (upper arm)

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 2 Installation and commissioning
2.5.1 Robot cabling and connection points

2.5 Electrical connections

2.5.1 Robot cabling and connection points

Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.
IRB 910SC works with IRC5 Compact controller only.

Main cable categories

All cables between the robot and controller are divided into the following categories:
Cable category Description
Robot cables Handles power supply to and control of the robot's motors
as well as feedback from the encoder interface board.
Specified in the table Robot cables on page 71.
Customer cables (option) Handles communication with equipment fitted on the robot
by the customer (low voltage signals).
The customer cables also handle Ethernet communication.
See Product manual - IRC5 Compact.

Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet
to the robot motors.
Robot cable, signals Transfers encoder data from XS2 R1.EIB
and power supply to the en-
coder interface board.

Robot cable, power

Power cable length Article number

3m 3HAC057784-001
7m 3HAC057785-001
15 m 3HAC057786-001

Robot cable, signals

Signal cable length Article number

3m 3HAC057787-001
7m 3HAC057788-001
15 m 3HAC057789-001

Continues on next page

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2 Installation and commissioning
2.5.1 Robot cabling and connection points
Continued

Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.

A
B

xx1600002016

A Diameter
B Diameter x10

Grounding and bonding point on manipulator

There is a grounding/bonding point on the manipulator base. The grounding/bonding
point is used for potential equalizing between control cabinet, manipulator and any
peripheral devices.

xx2100000706

Customer cables - CP/CS cable (option)

CP/CS cable length Article number

3 m (IRC5C) 3HAC049186-001
7 m (IRC5C) 3HAC049186-004
15 m (IRC5C) 3HAC049186-005

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 2 Installation and commissioning
2.5.2 Customer connections

2.5.2 Customer connections

Introduction to customer connections

The cables for customer connection are integrated in the robot and the connectors
are placed at the upper arm and base. There is one connector R3.CP/CS at the
upper arm. Corresponding connector R1.CP/CS is located at the base.
Hose for compressed air is also integrated into the manipulator. There are 4 inlets
at the base (R1/8”) and 4 outlets (M5) on the upper arm.

xx1500002751

Position Connection Description Number Value

A Air Max. 5 bar 4 Outer diameter of air hose:
4 mm
B (R1)R3.CP/CS Customer power/signal 10 49 V, 500 mA

Connectors
The tables describes the connectors on base and upper arm.

Connectors, base

Position Description Art. no.

Robot Pin connector 10p, bulkhead 3HAC022117-002
Customer connector Connector set R1.CP/CS 3HAC037038-001

Connectors, upper arm

Position Description Art. no.

Robot Socket connector 10p, flange mounted 3HAC023624-002
Customer connector Connector set R3.CP/CS 3HAC037070-001

Continues on next page

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2 Installation and commissioning
2.5.2 Customer connections
Continued

Air, connector

Position Description Art. no.

Robot 4xM5
Customer cable Air connector 3HAC032049-001

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 2 Installation and commissioning
2.6 Start of robot in cold environments

2.6 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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This page is intentionally left blank
 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
910SC.
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 17 before performing any service
work.
The maintenance must be done by qualified personnel in accordance with the
safety requirements set forth in the applicable national and regional standards and
regulations.

Note

If the IRB 910SC is connected to power, always make sure that the IRB 910SC
is connected to protective earth and a residual current device (RCD) before
starting any maintenance work.
For more information see:
• Product manual - IRC5 Compact
• Robot cabling and connection points on page 71.

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3 Maintenance
3.2 Service Information System (SIS)

3.2 Service Information System (SIS)

General
Service Information System (SIS) is a software function within the robot controller,
which simplifies maintenance of the robot system. It supervises the operating time
and mode of the robot, and alerts the operator when a maintenance activity is
scheduled.

Troubleshooting
The SIS function Gearbox is available for estimating the service interval (remaining
lifetime) of the gearboxes of a robot. Such information of the ball screw spline unit
of the IRB 910SC is reported as axis 3 in the SIS system. When a service message
is reported for axis 3 of the IRB 910SC, an inspection on the ball screw spline unit
is required.
For more information about the SIS function, see Operating manual - Service
Information System.

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 3 Maintenance
3.3.1 Specification of maintenance intervals

3.3 Maintenance schedule

3.3.1 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 910SC:
• 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.
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
3.3.2 Maintenance schedule

3.3.2 Maintenance schedule

Scheduled and non-predictable maintenance

The robot must be maintained regularly to ensure proper function. The maintenance
activities and intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages
must be attended to immediately!

Life of each component

The inspection intervals do not specify the life of each component.

Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals:

Every 20,000 hours ii

Every 12 months
Every 100 km
Regularly i

Maintenance activities Reference

Cleaning activities
Cleaning the IRB 910SC on
Cleaning the robot x
page 114
Inspection activities
Check for abnormal wear or
Inspecting the robot x
contamination.
Inspecting the robot cabling iii x iv Inspecting the cabling on page 82
Inspecting the information labels
Inspecting the information labels x
on page 83
Inspecting the ball screw spline
Inspecting the ball screw spline unit xv
unit on page 86
Inspecting axis-1 and axis-2
Inspecting the axis-1 and axis-2 mechanical stops x vi
mechanical stops on page 89
Inspecting the timing belts on
Inspecting the timing belts x
page 92
Replacement/changing activities
Replacing the battery pack on
Replacing the battery pack vii
page 100
Lubrication activities
Lubricating the ball screw spline
Lubricating the ball screw spline unit x
unit on page 111
Overhaul

Continues on next page

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 3 Maintenance
3.3.2 Maintenance schedule
Continued

Every 20,000 hours ii

Every 12 months
Every 100 km
Regularly i
Maintenance activities Reference

Overhaul of complete robot x

i "Regularly" implies that the activity is to be performed regularly, but the actual interval may not be
specified by the robot manufacturer. The interval depends on the operation cycle of the robot, its
working environment and movement pattern. Generally, the more contaminated environment, the
shorter intervals. The more demanding movement pattern (sharper bending cable harness), the
shorter intervals.
ii Operating hours counted by the DTC = Duty time counter.
iii The robot cabling comprises the cabling between the robot and controller cabinet.
iv Replace when damage or cracks is detected or life limit is approaching.
v Inspect immidiately if the stop blocks are hit.
vi Inspect immidiately if the mechanical stop is hit.
vii The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. Typical life 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 hours/day. The life can be
extended (approximately 3 times) for longer production breaks by a battery shutdown service
routine. See Operating manual - IRC5 with FlexPendant.
See the replacement instruction for more details.

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3 Maintenance
3.4.1 Inspecting the cabling

3.4 Inspection activities

3.4.1 Inspecting the cabling

Location of robot cabling

The robot cabling comprises the cabling between the robot and controller cabinet
as well as the externally visible cabling from the base to the upper arm.

Required tools and equipment

Visual inspection, no tools are required.
Other tools and procedures may be required if the spare part needs to be replaced.
These are specified in the replacement procedure.

Inspection, robot cabling

Use this procedure to inspect the robot cabling.
Action Note
1
DANGER

Turn off all:

• electric power supply to the robot
• hydraulic pressure supply to the robot
• air pressure supply to the robot
Before entering the robot working area.

2 Visually inspect:
• the control cabling between the robot and
control cabinet
• the externally visible cabling from the base
to the upper arm
Look for abrasions, cuts or crush damages.
3 Replace the cabling if wear or damage is detected. See Replacing the main cable
package on page 122.

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 3 Maintenance
3.4.2 Inspecting the information labels

3.4.2 Inspecting the information labels

Location of labels
This figure shows the location of the information labels to be inspected. The symbols
are described in section Safety symbols on manipulator labels on page 21.

 
(D)
(E)
Absolute Accuracy UL label

(B)
Axis Resolver values

ABB
Robotics
(A) (A) Lifting
Products AB Warning
Tilt introduction
warning label
label

(F) (G) (C)

(H) (J) (K)

(B)
(C)

(L)

xx1500002258

Pos Description Illustration

A ABB logo, large size
B ABB logo, small size
C Synchronization mark for axis 2

xx1500002671

Synchronization mark for axis 3 and 4

xx1500002672

D AbsAcc label
E Calibration label

Continues on next page

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3 Maintenance
3.4.2 Inspecting the information labels
Continued

F Warning label
Tip risk when loosening bolts


6XSSOHPHQWDU\GRFXPHQW 'RFW\SH 'RFXPHQW 'HVFULSWLRQ

xx1500002402


G Rating label
H UL label
J Instruction label
Lifting of robot 

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+$&
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GLVFORVXUHWRWKLUGSDUWLHVZLWKRXWH[SUHVVDXWKRULW\
IRUPDWLRQFRQWDLQHGWKHUHLQ5HSURGXFWLRQXVHRU

LVVWULFWO\IRUELGGHQ‹$%%&RS\ULJKW

xx1600000282

K Instruction label
Brake release
Moving robot
Brake release buttons
7H[W$ULDO1DUURZPP
ⷦ⇢$ULDO1DUURZ⹌PP
0DWHULDO3ODVWLFEDVHGILOPIRUGLJLWDOSULQWPDWWILQLVK
㧟㠨♾㓢◿䤓⫠㠨堓❠槱
6\PERO%ODFNSULQWRQZKLWHERWWRP
⦍㫗䤌ㄤ煠唁㓢◿

1HZ xx1500002403

L Warning label
Flash /DWHVW5HYLVLRQ
3UHSDUHG 5HVSRQVLEOH'HSDUWPHQW 'HVFULSWLRQ 6:' 'U
-:X '052&150
$SSURYHG 7DNHRYHUGHSDUWPHQW
xx1300001091 /LIWLQJLQWUXGXFWLRQODEHOIRU,5%6&
6WDWXV (&2QXPEHU

'UDIW 
'RFXPHQWQR

+$&
Continues on next page
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 3 Maintenance
3.4.2 Inspecting the information labels
Continued

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

ABB logo, small size 3HAC0453-6
ABB logo, large size 3HAC0453-2
Warning label 3HAC057068-001 Risk of tipping
Warning sign 3HAC1589-1 Electrical shock
Rating label 3HAB9549-1
UL label 3HAC037252-001
Lifting label 3HAC058299-001
Instruction label 3HAC057070-001 Break release, moving robot
Calibration label 3HAC13488-1
Calibration mark (axis 2) 3HAC057089-001
Calibration mark (axis 3 and axis 3HAC057090-001
4)

Required tools and equipment

Visual inspection, no tools are required.

Inspecting, labels

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

2 Inspect the labels, located as shown in the figures. See the figures in Location of la-
bels on page 83.
3 Replace any missing or damaged labels.

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3 Maintenance
3.4.3 Inspecting the ball screw spline unit

3.4.3 Inspecting the ball screw spline unit

Location of ball screw spline unit

xx1500002212

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Ball screw spline unit 3HAC056148-001

Required tools and equipment

Equipment Note
24 VDC power supply Used to release the motor brakes.
Other tools and procedures may be required
if the spare part needs to be replaced. These
are specified in the replacement procedure.

Continues on next page

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 3 Maintenance
3.4.3 Inspecting the ball screw spline unit
Continued

Inspecting, ball screw spline unit

Action Note
1 Turn on the electric power to the robot.
If the robot is not connected to the controller, power
must be supplied to the connector R1.MP according
to the section Supplying power to connector R1.MP
on page 62.
2
DANGER

When releasing the holding brakes, the robot axes

may move very quickly and sometimes in unexpec-
ted ways!
Make sure the payload is disassembled or tooling
is properly supported; otherwise, fast downward
movements of axis 3 may cause severe hits.

3 Release the holding brake by pressing the button

on the internal brake release unit.

xx1500002774

4 Move the upper arm to a position where the axis 3

can be moved in full stroke.
5 Press the brake release button and move the shaft
to its upper and lower limits manually.

xx1500002774

6 Visually inspect:
• the stop blocks on the ball screw spline unit
• the shaft of the ball screw spline unit
Look for abrasions, cuts or crush damages on the
spline, and grease amount on the shaft.

xx1500002778

A Upper stop block

B Shaft
C Lower stop block

Continues on next page

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3 Maintenance
3.4.3 Inspecting the ball screw spline unit
Continued

Action Note
7 Apply grease to the shaft if it is not enough. See Lubricating the ball screw
spline unit on page 111.

xx1500002779

8 Replace the ball screw spline unit if wear or dam- See Replacing the ball screw
age is detected. spline unit on page 229.

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 3 Maintenance
3.4.4 Inspecting axis-1 and axis-2 mechanical stops

3.4.4 Inspecting axis-1 and axis-2 mechanical stops

Location of axis-1 and axis-2 mechanical stops

The mechanical stops on axes 1 and 2 are located as shown in the figures.

Axis 1

Axis-1 mechanical stop block Axis-1 mechanical stop rubber

xx1500002177 xx1500002176

Axis 2

Axis-2 mechanical stop block Axis-2 mechanical stop rubber

xx1500002175 xx1500002174

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Axis-1 mechanical stop rubber 3HAC056042-001 Replace if damaged.
Axis-1 mechanical stop block 3HAC055164-001 Replace if damaged.
Axis-2 mechanical stop rubber 3HAC056017-001 Replace if damaged.
Axis-2 mechanical stop block 3HAC055185-001 Replace if damaged.

Continues on next page

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3 Maintenance
3.4.4 Inspecting axis-1 and axis-2 mechanical stops
Continued

Required tools and equipment

Visual inspection, no tools are required.
Other tools and procedures may be required if the spare part needs to be replaced.
These are specified in the replacement procedure.

Inspecting, axis-1 and axis-2 mechanical stops

Use this procedure to inspect mechanical stops on axes 1 and 2.
Action Information
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

2 Inspect the mechanical stops.

xx1500002783

A Axis-1 mechanical stop rub-

bers
B Axis-2 mechanical stop rub-
bers

xx1500002784

A Axis-1 mechanical stop block

B Axis-2 mechanical stop block

Continues on next page

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 3 Maintenance
3.4.4 Inspecting axis-1 and axis-2 mechanical stops
Continued

Action Information
3 Replace if any mechanical stop is:
• bent
• loose
• damaged.

Note

The expected life of gearboxes can be reduced as

a result of collisions with the mechanical stop.

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3 Maintenance
3.4.5 Inspecting the timing belts

3.4.5 Inspecting the timing belts

Location of timing belts

The timing belts are located as shown in the figures.
Axis-3 timing belt Upper axis-4 timing belt Lower axis-4 timing belt

xx1500002218 xx1500002216 xx1500002217

Required tools and equipment

Equipment Note
Standard toolkit The content is defined in the section Stand-
ard toolkit on page 386.
Sonic tensiometer Used for measuring the timing belt tension.
Other tools and procedures may be required
if the spare part needs to be replaced. These
are specified in the replacement procedure.

Timing belt tension

The table describes the timing belt tension.
Axis Timing belt tension
Axis 3 Recommended: 34 N
Tension range of new belt: 31.1 to 34.2 N
Tension range of used belt i : 21.8 N to 24.9
N
Axis 4 Upper timing belt
Recommended: 37 N
Tension range of new belt: 34.5 N to 37.9 N
Tension range of used belt i : 24.1 N to 27.6
N
Lower timing belt
Recommended: 101 N
Tension range of new belt: 92.2 N to 101 N
Tension range of used belt i : 64.5 N to 73.7
N
i Used belt is the one having been installed and used for more than 24 hours.

Continues on next page

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 3 Maintenance
3.4.5 Inspecting the timing belts
Continued

Inspecting timing belts

Use this procedure to inspect timing belts.

Preparations before inspecting timing belts

Action Note
1 Jog axis 2 to access the cover screws.

xx1500002520

xx1500002782

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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3 Maintenance
3.4.5 Inspecting the timing belts
Continued

Removing the main cable package from the upper arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the dome nuts and washers.

xx1500002182

3 Carefully open the user interface plate and

pull out the cable package.

CAUTION

The plate cannot be removed completely

until the connectors are disconnected, as
shown in the following step.

xx1500002183

Continues on next page

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 3 Maintenance
3.4.5 Inspecting the timing belts
Continued

Action Note
4 Disconnect the connectors:
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

Tip

Take photos of the connectors and cable xx1500002184

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002185

Removing the upper cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the robot is well

secured and that the upper arm is suppor-
ted during the removal work.

3 Remove the screws.

xx1500002220

Continues on next page

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3 Maintenance
3.4.5 Inspecting the timing belts
Continued

Action Note
4
WARNING

The cover may be damaged due to improp-

er shift. Keep the cover in position while
removing the screws.

5 Lift out the upper cover carefully.

xx1500002221

Removing the lower cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws.

xx1500002785

3 Remove the cover.

Tip

If only working with lower axis-4 timing belt,

no need to remove the stop block of ball
screw spline unit before removing the lower
cover.

xx1500002225

Continues on next page

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 3 Maintenance
3.4.5 Inspecting the timing belts
Continued

Inspecting timing belts

Action Information
1 Check the timing belts for damage or wear.

xx1500002218

xx1500002216

xx1500002217

Continues on next page

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3 Maintenance
3.4.5 Inspecting the timing belts
Continued

Action Information
2 Check the timing belt pulleys for damage.

xx1500002780

xx1500002781

3 If any damage or wear is detected, the part

must be replaced!
4 Check each belt for tension. Timing belt tensions are specified in Tim-
ing belt tension on page 92.

Continues on next page

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 3 Maintenance
3.4.5 Inspecting the timing belts
Continued

Action Information
5 If the belt tension is not correct, adjust
screws while using a sonic tensiometer to
measure the belt tension until a proper belt
tension is achieved!

xx1500002229

xx1500002233

xx1500002231

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3 Maintenance
3.5.1 Replacing the battery pack

3.5 Replacement/changing activities

3.5.1 Replacing the battery pack

Note

The battery low alert (38213 Battery charge low) is displayed when remaining
backup capacity (robot powered off) is less than 2 months. Typical life 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 hours/day. The life can be extended (approximately 3
times) for longer production breaks by a battery shutdown service routine. See
Operating manual - IRC5 with FlexPendant.

Location of the battery pack

The battery pack is located as shown in the figure.

xx1500002180

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Continues on next page

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 3 Maintenance
3.5.1 Replacing the battery pack
Continued

Spare part Article number Note

Battery pack 3HAC051036-001 Battery includes protection cir-
cuits. Only replace with a spe-
cified spare part or an ABB-ap-
proved equivalent.

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Required consumables
Consumable Article number Note
Cable ties -

Removing the battery pack

Use these procedures to remove the battery pack.

Preparations before removing the battery pack

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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3 Maintenance
3.5.1 Replacing the battery pack
Continued

Removing the main cable package from the base

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws and washers.

xx1500002186

3 Carefully open the base cover and pull out

the cable package.

CAUTION

The cover cannot be removed completely

until the connectors are disconnected.

CAUTION

Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail-
ures. xx1500002187

4 Disconnect the connectors:

• R2.MP1
• R2.ME1

Tip

Take photos of the connectors and cable

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002188

Continues on next page

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 3 Maintenance
3.5.1 Replacing the battery pack
Continued

Removing the PCB board

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

3 Disconnect the connectors:

• R1.BK1-2
• R1.DBP
• R2.BK1-2

Tip

Take photos of the connectors and cable

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002190

A R1.BK1-2
B R1.DBP
C R2.BK1-2

Continues on next page

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3 Maintenance
3.5.1 Replacing the battery pack
Continued

Action Note
4 Cut the cable ties.

xx1500002752

5 Remove the PCB board carefully.

xx1500002191

Disconnecting the battery cable

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

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 3 Maintenance
3.5.1 Replacing the battery pack
Continued

Action Note
3 Disconnect the battery cable.

xx1500002192

Removing the battery pack

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

3 Cut the cable ties.

xx1500002193

Continues on next page

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3 Maintenance
3.5.1 Replacing the battery pack
Continued

Action Note
4 Remove the battery.

Note

Battery includes protection circuits. Only

replace with a specified spare part or with
an ABB- approved equivalent.

xx1500002194

Refitting the battery pack

Use these procedures to refit the battery pack.

Refitting the battery pack

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

2 Fit the battery.

Note

Battery includes protection circuits. Only

replace with a specified spare part or with
an ABB- approved equivalent.

xx1500002206

Continues on next page

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 3 Maintenance
3.5.1 Replacing the battery pack
Continued

Action Note
3 Secure the battery with cable ties.

xx1500002193

Connecting the battery cable

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

2 Connect the battery cable.

xx1500002192

Continues on next page

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3 Maintenance
3.5.1 Replacing the battery pack
Continued

Refitting the PCB board

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

2 Refit the PCB board. PCB board: 3HAC057687-001

Note

The PCB board is protected by shrink hose.

Replace the hose if damaged.

xx1500002205

3 Secure the PCB board with cable ties.

Do not tighten the ties too tight.

xx1500002752

Continues on next page

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 3 Maintenance
3.5.1 Replacing the battery pack
Continued

Action Note
4 Reconnect the connectors.
• R1.BK1-2
• R1.DBP
• R2.BK1-2

CAUTION

Make sure not to mix the connectors. See

the labels on the connectors for correct
connection.

xx1500002190

A R1.BK1-2
B R1.DBP
C R2.BK1-2

5 Secure the cables with cable ties if needed.

Refitting the main cable to the base

Action Note
1 Secure the main cable package with cable
ties if needed.
2 Reconnect the connectors.
• R2.MP1
• R2.ME1

xx1500002188

Continues on next page

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3 Maintenance
3.5.1 Replacing the battery pack
Continued

Action Note
3 Push the main cable package into place.

xx1500002204

4 Refit the base cover with screws and

washers.

xx1500002186

Screws: M4x10 (6 pcs)

Tightening torque: 2 Nm

Concluding procedure

Action Note
1 Update the revolution counters. See Updating revolution counters on
page 351.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

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 3 Maintenance
3.6.1 Lubricating the ball screw spline unit

3.6 Lubrication activities

3.6.1 Lubricating the ball screw spline unit

Location of the ball screw spline unit

The ball screw spline unit is located as shown in the figure.

xx1500002212

Required tools and equipment

Equipment Article number Note

24 VDC power supply - Used to release the motor brakes.

Required consumables
Consumable Article number Note
Grease - THK AFA
Used for lubricating the ball screw
spline shaft.

Lubricating the ball screw spline unit

Note

Cover the end effector and peripheral equipment in case the grease drips, before
lubricating the ball screw spline unit.

Continues on next page

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3 Maintenance
3.6.1 Lubricating the ball screw spline unit
Continued

Action Note
1 Turn on the electric power to the robot.
If the robot is not connected to the controller, power
must be supplied to the connector R1.MP according
to the section Supplying power to connector R1.MP
on page 62.
2
DANGER

When releasing the holding brakes, the robot axes

may move very quickly and sometimes in unexpec-
ted ways!
Make sure the payload is disassembled or tooling
is properly supported; otherwise, fast downward
movements of axis 3 may cause severe hits.

3 Release the holding brake by pressing the button

on the internal brake release unit.

xx1500002774

4 Move the upper arm to a position where the axis 3

can be moved in full stroke.
5 Move the shaft manually to its upper limit while
pressing the brake release button.

xx1500002790

6 Wipe off old grease from the shaft.

7 Apply new grease and fill the grooves. Wipe off
excessive grease.
8 Move the shaft manually to its lower limit while
pressing the brake release button.

xx1500002791

9 Wipe off old grease from the shaft.

10 Apply new grease and fill the grooves. Wipe off
excessive grease.

Continues on next page

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 3 Maintenance
3.6.1 Lubricating the ball screw spline unit
Continued

Action Note
11 Move the shaft up and down several times while
pressing the brake release button to smooth out
the grease on the shaft. Wipe off excessive grease.

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3 Maintenance
3.7.1 Cleaning the IRB 910SC

3.7 Cleaning activities

3.7.1 Cleaning the IRB 910SC

DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the safeguarded space.

General
To secure high uptime it is important that the IRB 910SC is cleaned regularly. The
frequency of cleaning depends on the environment in which the product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 910SC.

Note

Always verify the protection type of the robot before cleaning.

Special cleaning considerations

This section specifies some special considerations when cleaning the robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning.
• Never point the water jet at connectors, joints, sealings, or gaskets.
• Do not use compressed air to clean the robot.
• Never use solvents that are not approved by ABB to clean the robot.
• Do not spray from a distance closer than 0.4 m.
• Do not remove any covers or other protective devices before cleaning the
robot.

Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.
Protection Cleaning method
type
Vacuum Wipe with cloth Rinse with water High pressure water or
cleaner steam
Standard Yes Yes. With light No No
IP20 cleaning deter-
gent.

Continues on next page

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 3 Maintenance
3.7.1 Cleaning the IRB 910SC
Continued

Cables
Movable cables need to be able to move freely:
• Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
• Clean the cables if they have a crusty surface, for example from dry release
agents.

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This page is intentionally left blank
 4 Repair
4.1 Introduction

4 Repair
4.1 Introduction

Structure of this chapter

This chapter describes repair activities for the IRB 910SC. 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 910SC, 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 17 before commencing any
service work.

Note

If the IRB 910SC is connected to power, always make sure that the IRB 910SC
is connected to protective earth and a residual current device (RCD) before
starting any repair work.
For more information see:
• Product manual - IRC5 Compact

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

4.2 General procedures

4.2.1 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.

Required equipment

Equipment Spare parts Note

Cleaning agent Ethanol
Knife
Lint free cloth
Touch up paint Standard/Foundry 3HAC067974-001 Graphite White
Plus

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.

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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 3HAC042536-001 Shell Gadus S2

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

CAUTION

Please observe the following before commencing any assembly of sealings:

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

Action Note
1 Check the sealing to ensure that:
• The sealing is of the correct type.
• There is no damage on the main lip.
2 Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.
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 119.
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

Continues on next page

Product manual - IRB 910SC 119
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.2.2 Mounting instructions for sealings
Continued

Action Note
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

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.

Continues on next page

120 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.2.2 Mounting instructions for sealings
Continued

Action Note
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.

Product manual - IRB 910SC 121

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package

4.3 Cable harness

4.3.1 Replacing the main cable package

Location of the main cable package

The main cable package is located as shown in the figure.

xx1500002172

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Main cable, 450 mm 3HAC056165-001
Main cable, 550 mm 3HAC056080-001
Main cable, 650 mm 3HAC056166-001
EIB connection cable 3HAC056703-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Continues on next page

122 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Required consumables
Consumable Article number Note
Shrink hose - Used for protecting the PCB
board.
Cable ties -

Removing the main cable package

Use these procedures to remove the main cable package.

Preparations before removing the main cable package

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the main cable package from the upper arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

Product manual - IRB 910SC 123
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
2 Remove the dome nuts and washers.

xx1500002182

3 Carefully open the user interface plate and

pull out the cable package.

CAUTION

The plate cannot be removed completely

until the connectors are disconnected, as
shown in the following step.

xx1500002183

4 Disconnect the connectors:

• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

Tip

Take photos of the connectors and cable xx1500002184

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002185

Continues on next page

124 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Removing the main cable package from the base

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws and washers.

xx1500002186

3 Carefully open the base cover and pull out

the cable package.

CAUTION

The cover cannot be removed completely

until the connectors are disconnected.

CAUTION

Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail-
ures. xx1500002187

4 Disconnect the connectors:

• R2.MP1
• R2.ME1

Tip

Take photos of the connectors and cable

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002188

Continues on next page

Product manual - IRB 910SC 125
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package
Continued

Removing the PCB board

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

3 Disconnect the connectors:

• R1.BK1-2
• R1.DBP
• R2.BK1-2

Tip

Take photos of the connectors and cable

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002190

A R1.BK1-2
B R1.DBP
C R2.BK1-2

Continues on next page

126 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
4 Cut the cable ties.

xx1500002752

5 Remove the PCB board carefully.

xx1500002191

Disconnecting the battery cable

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

Product manual - IRB 910SC 127
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
3 Disconnect the battery cable.

xx1500002192

Removing the battery pack

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

3 Cut the cable ties.

xx1500002193

Continues on next page

128 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
4 Remove the battery.

Note

Battery includes protection circuits. Only

replace with a specified spare part or with
an ABB- approved equivalent.

xx1500002194

Removing the EIB unit

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

Product manual - IRB 910SC 129
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
3 Disconnect the connectors:
• R1.EIB
• R1.ME4
• R1.ME1-3

xx1500002195

A R1.EIB
B R1.ME4
C R1.ME1-3

4 Remove the screws.

xx1500002792

Continues on next page

130 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
5 Remove the EIB unit.

xx1500002196

6 Disconnect the connector to remove the

EIB connection cable.
• R2.EIB

xx1500002197

A R2.EIB

Removing the EIB mounting plate

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

Product manual - IRB 910SC 131
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
2 Disconnect the earth cable by removing
the screw.

xx1500002794

3 Remove the screws.

xx1500002795

4 Remove the EIB mounting plate.

xx1500002198

Continues on next page

132 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Removing the floor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws and washers.

xx1500002199

3 Pull out the floor cables.

xx1500002200

Disconnecting the floor cable connector

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

Product manual - IRB 910SC 133
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
2 Disconnect the connector:
• R1.MP

xx1500002201

A R1.MP

Refitting the main cable package

Use these procedures to refit the main cable package.

Reconnecting the floor cable connector

Action Note
1 Reconnect the connector.
• R1.MP

xx1500002201

A R1.MP

Continues on next page

134 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Refitting the floor cables

Action Note
1 Push the floor cables into place.

xx1500002208

2 Secure with screws and washers.

xx1500002199

Screw: M4x10 (4 pcs)

Tightening torque: 2 Nm

Continues on next page

Product manual - IRB 910SC 135
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package
Continued

Refitting the EIB mounting plate

Action Note
1 Refit the EIB mounting plate. EIB mounting plate: 3HAC055165-001

xx1500002796

2 Secure with screws.

xx1500002795

Screw: M3x6 (2 pcs)

Tightening torque: 1.5 Nm

Continues on next page

136 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
3 Connect the earth cable with the screw.

xx1500002794

Screw: M3x4 (1 pcs)

Tightening torque: 0.3 Nm

Refitting the EIB unit

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

Product manual - IRB 910SC 137
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
2 Reconnect the connector to refit the EIB EIB connection cable: 3HAC056703-001
connection cable.
• R2.EIB

CAUTION

The EIB connection cable has one connect-

or at one end and two connectors at the
other end.
Make sure not to mix the connectors. See
the labels on the connectors for correct
connection.

xx1500002197

A R2.EIB

3 Refit the EIB unit.

xx1500002793

Continues on next page

138 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
4 Secure with screws.

xx1500002792

Screw: M3x8 (4 pcs)

Tightening torque: 0.3 Nm
5 Reconnect the connectors.
• R1.EIB
• R1.ME4
• R1.ME1-3

CAUTION

Make sure not to mix the connectors; oth-

erwise, axes may be damaged. See the la-
bels on the connectors for correct connec-
tion.

xx1500002195

A R1.EIB
B R1.ME4
C R1.ME1-3

Refitting the battery pack

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

Product manual - IRB 910SC 139
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
2 Fit the battery.

Note

Battery includes protection circuits. Only

replace with a specified spare part or with
an ABB- approved equivalent.

xx1500002206

3 Secure the battery with cable ties.

xx1500002193

Connecting the battery cable

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

140 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
2 Connect the battery cable.

xx1500002192

Refitting the PCB board

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

2 Refit the PCB board. PCB board: 3HAC057687-001

Note

The PCB board is protected by shrink hose.

Replace the hose if damaged.

xx1500002205

Continues on next page

Product manual - IRB 910SC 141
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
3 Secure the PCB board with cable ties.
Do not tighten the ties too tight.

xx1500002752

4 Reconnect the connectors.

• R1.BK1-2
• R1.DBP
• R2.BK1-2

CAUTION

Make sure not to mix the connectors. See

the labels on the connectors for correct
connection.

xx1500002190

A R1.BK1-2
B R1.DBP
C R2.BK1-2

5 Secure the cables with cable ties if needed.

Refitting the main cable to the base

Action Note
1 Secure the main cable package with cable
ties if needed.

Continues on next page

142 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
2 Reconnect the connectors.
• R2.MP1
• R2.ME1

xx1500002188

3 Push the main cable package into place.

xx1500002204

4 Refit the base cover with screws and

washers.

xx1500002186

Screws: M4x10 (6 pcs)

Tightening torque: 2 Nm

Refitting the main cable to the upper arm

Action Note
1 Secure the main cable package with cable
ties if needed.

Continues on next page

Product manual - IRB 910SC 143
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.1 Replacing the main cable package
Continued

Action Note
2 Reconnect the connectors.
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

xx1500002184

xx1500002185

3 Push the main cable package into place.

xx1500002207

4 Refit the user interface plate.

xx1500002182

Dome nut: M4 (6 pcs)

Tightening torque: 2 Nm
Washer, 6 pcs

Continues on next page

144 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.1 Replacing the main cable package
Continued

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

Product manual - IRB 910SC 145

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.2 Replacing the EIB unit

4.3.2 Replacing the EIB unit

Location of the EIB unit

The EIB unit is located as shown in the figure.

xx1500002178

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

EIB unit 3HAC045759-001
EIB connection cable 3HAC056703-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Required consumables
Consumable Article number Note
Cable ties -

Continues on next page

146 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.2 Replacing the EIB unit
Continued

Removing the EIB unit

Use these procedures to remove the EIB unit.

Preparations before removing the EIB unit

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the main cable package from the base

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws and washers.

xx1500002186

Continues on next page

Product manual - IRB 910SC 147
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.2 Replacing the EIB unit
Continued

Action Note
3 Carefully open the base cover and pull out
the cable package.

CAUTION

The cover cannot be removed completely

until the connectors are disconnected.

CAUTION

Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail-
ures. xx1500002187

4 Disconnect the connectors:

• R2.MP1
• R2.ME1

Tip

Take photos of the connectors and cable

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002188

Disconnecting the battery cable

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

148 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.2 Replacing the EIB unit
Continued

Action Note
3 Disconnect the battery cable.

xx1500002192

Removing the EIB unit

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

Product manual - IRB 910SC 149
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.2 Replacing the EIB unit
Continued

Action Note
3 Disconnect the connectors:
• R1.EIB
• R1.ME4
• R1.ME1-3

xx1500002195

A R1.EIB
B R1.ME4
C R1.ME1-3

4 Remove the screws.

xx1500002792

Continues on next page

150 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.2 Replacing the EIB unit
Continued

Action Note
5 Remove the EIB unit.

xx1500002196

6 Disconnect the connector to remove the

EIB connection cable.
• R2.EIB

xx1500002197

A R2.EIB

Continues on next page

Product manual - IRB 910SC 151
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.2 Replacing the EIB unit
Continued

Refitting the EIB unit

Use these procedures to refit the EIB unit.

Refitting the EIB unit

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

2 Reconnect the connector to refit the EIB EIB connection cable: 3HAC056703-001
connection cable.
• R2.EIB

CAUTION

The EIB connection cable has one connect-

or at one end and two connectors at the
other end.
Make sure not to mix the connectors. See
the labels on the connectors for correct
connection.

xx1500002197

A R2.EIB

3 Refit the EIB unit.

xx1500002793

Continues on next page

152 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.2 Replacing the EIB unit
Continued

Action Note
4 Secure with screws.

xx1500002792

Screw: M3x8 (4 pcs)

Tightening torque: 0.3 Nm
5 Reconnect the connectors.
• R1.EIB
• R1.ME4
• R1.ME1-3

CAUTION

Make sure not to mix the connectors; oth-

erwise, axes may be damaged. See the la-
bels on the connectors for correct connec-
tion.

xx1500002195

A R1.EIB
B R1.ME4
C R1.ME1-3

Connecting the battery cable

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

Product manual - IRB 910SC 153
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.2 Replacing the EIB unit
Continued

Action Note
2 Connect the battery cable.

xx1500002192

Refitting the main cable to the base

Action Note
1 Secure the main cable package with cable
ties if needed.
2 Reconnect the connectors.
• R2.MP1
• R2.ME1

xx1500002188

3 Push the main cable package into place.

xx1500002204

Continues on next page

154 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.2 Replacing the EIB unit
Continued

Action Note
4 Refit the base cover with screws and
washers.

xx1500002186

Screws: M4x10 (6 pcs)

Tightening torque: 2 Nm

Concluding procedure

Action Note
1 Update the revolution counters. See Updating revolution counters on
page 351.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

Product manual - IRB 910SC 155

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.3 Replacing the PCB board

4.3.3 Replacing the PCB board

Location of the PCB board

The PCB board is located as shown in the figure.

xx1500002179

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

PCB board 3HAC057687-001

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Required consumables
Consumable Article number Note
Shrink hose - Used for protecting the PCB
board.
Cable ties -

Continues on next page

156 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.3 Replacing the PCB board
Continued

Removing the PCB board

Use these procedures to remove the PCB board.

Preparations before removing the PCB board

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the main cable package from the base

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws and washers.

xx1500002186

Continues on next page

Product manual - IRB 910SC 157
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.3 Replacing the PCB board
Continued

Action Note
3 Carefully open the base cover and pull out
the cable package.

CAUTION

The cover cannot be removed completely

until the connectors are disconnected.

CAUTION

Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail-
ures. xx1500002187

4 Disconnect the connectors:

• R2.MP1
• R2.ME1

Tip

Take photos of the connectors and cable

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002188

Removing the PCB board

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

158 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.3 Replacing the PCB board
Continued

Action Note
3 Disconnect the connectors:
• R1.BK1-2
• R1.DBP
• R2.BK1-2

Tip

Take photos of the connectors and cable

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002190

A R1.BK1-2
B R1.DBP
C R2.BK1-2

4 Cut the cable ties.

xx1500002752

Continues on next page

Product manual - IRB 910SC 159
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.3 Replacing the PCB board
Continued

Action Note
5 Remove the PCB board carefully.

xx1500002191

Refitting the PCB board

Use these procedures to refit the PCB board.

Refitting the PCB board

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

2 Refit the PCB board. PCB board: 3HAC057687-001

Note

The PCB board is protected by shrink hose.

Replace the hose if damaged.

xx1500002205

Continues on next page

160 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.3 Replacing the PCB board
Continued

Action Note
3 Secure the PCB board with cable ties.
Do not tighten the ties too tight.

xx1500002752

4 Reconnect the connectors.

• R1.BK1-2
• R1.DBP
• R2.BK1-2

CAUTION

Make sure not to mix the connectors. See

the labels on the connectors for correct
connection.

xx1500002190

A R1.BK1-2
B R1.DBP
C R2.BK1-2

5 Secure the cables with cable ties if needed.

Refitting the main cable to the base

Action Note
1 Secure the main cable package with cable
ties if needed.

Continues on next page

Product manual - IRB 910SC 161
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.3 Replacing the PCB board
Continued

Action Note
2 Reconnect the connectors.
• R2.MP1
• R2.ME1

xx1500002188

3 Push the main cable package into place.

xx1500002204

4 Refit the base cover with screws and

washers.

xx1500002186

Screws: M4x10 (6 pcs)

Tightening torque: 2 Nm

Concluding procedure

Action Note
1 Update the revolution counters. See Updating revolution counters on
page 351.

Continues on next page

162 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.3 Replacing the PCB board
Continued

Action Note
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

Product manual - IRB 910SC 163

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.4 Replacing the EIB mounting plate

4.3.4 Replacing the EIB mounting plate

Location of the EIB mounting plate

The EIB mounting plate is located as shown in the figure.

xx1500002517

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

EIB mounting plate 3HAC055165-001
EIB connection cable 3HAC056703-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Required consumables
Consumable Article number Note
Cable ties -

Continues on next page

164 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Removing the EIB mounting plate

Use these procedures to remove the EIB mounting plate.

Preparations before removing the EIB mounting plate

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the main cable package from the base

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws and washers.

xx1500002186

Continues on next page

Product manual - IRB 910SC 165
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
3 Carefully open the base cover and pull out
the cable package.

CAUTION

The cover cannot be removed completely

until the connectors are disconnected.

CAUTION

Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail-
ures. xx1500002187

4 Disconnect the connectors:

• R2.MP1
• R2.ME1

Tip

Take photos of the connectors and cable

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002188

Removing the PCB board

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

166 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
3 Disconnect the connectors:
• R1.BK1-2
• R1.DBP
• R2.BK1-2

Tip

Take photos of the connectors and cable

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002190

A R1.BK1-2
B R1.DBP
C R2.BK1-2

4 Cut the cable ties.

xx1500002752

Continues on next page

Product manual - IRB 910SC 167
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
5 Remove the PCB board carefully.

xx1500002191

Disconnecting the battery cable

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

3 Disconnect the battery cable.

xx1500002192

Continues on next page

168 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Removing the battery pack

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

3 Cut the cable ties.

xx1500002193

4 Remove the battery.

Note

Battery includes protection circuits. Only

replace with a specified spare part or with
an ABB- approved equivalent.

xx1500002194

Continues on next page

Product manual - IRB 910SC 169
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Removing the EIB unit

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

3 Disconnect the connectors:

• R1.EIB
• R1.ME4
• R1.ME1-3

xx1500002195

A R1.EIB
B R1.ME4
C R1.ME1-3

Continues on next page

170 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
4 Remove the screws.

xx1500002792

5 Remove the EIB unit.

xx1500002196

Continues on next page

Product manual - IRB 910SC 171
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
6 Disconnect the connector to remove the
EIB connection cable.
• R2.EIB

xx1500002197

A R2.EIB

Removing the EIB mounting plate

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Disconnect the earth cable by removing

the screw.

xx1500002794

Continues on next page

172 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
3 Remove the screws.

xx1500002795

4 Remove the EIB mounting plate.

xx1500002198

Continues on next page

Product manual - IRB 910SC 173
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Refitting the EIB mounting plate

Use these procedures to refit the EIB mounting plate.

Refitting the EIB mounting plate

Action Note
1 Refit the EIB mounting plate. EIB mounting plate: 3HAC055165-001

xx1500002796

2 Secure with screws.

xx1500002795

Screw: M3x6 (2 pcs)

Tightening torque: 1.5 Nm

Continues on next page

174 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
3 Connect the earth cable with the screw.

xx1500002794

Screw: M3x4 (1 pcs)

Tightening torque: 0.3 Nm

Refitting the EIB unit

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

Product manual - IRB 910SC 175
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
2 Reconnect the connector to refit the EIB EIB connection cable: 3HAC056703-001
connection cable.
• R2.EIB

CAUTION

The EIB connection cable has one connect-

or at one end and two connectors at the
other end.
Make sure not to mix the connectors. See
the labels on the connectors for correct
connection.

xx1500002197

A R2.EIB

3 Refit the EIB unit.

xx1500002793

Continues on next page

176 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
4 Secure with screws.

xx1500002792

Screw: M3x8 (4 pcs)

Tightening torque: 0.3 Nm
5 Reconnect the connectors.
• R1.EIB
• R1.ME4
• R1.ME1-3

CAUTION

Make sure not to mix the connectors; oth-

erwise, axes may be damaged. See the la-
bels on the connectors for correct connec-
tion.

xx1500002195

A R1.EIB
B R1.ME4
C R1.ME1-3

Refitting the battery pack

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

Product manual - IRB 910SC 177
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
2 Fit the battery.

Note

Battery includes protection circuits. Only

replace with a specified spare part or with
an ABB- approved equivalent.

xx1500002206

3 Secure the battery with cable ties.

xx1500002193

Connecting the battery cable

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

Continues on next page

178 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
2 Connect the battery cable.

xx1500002192

Refitting the PCB board

Action Note
1
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before hand-

ling the unit please read the safety inform-
ation in the section The unit is sensitive to
ESD on page 52

2 Refit the PCB board. PCB board: 3HAC057687-001

Note

The PCB board is protected by shrink hose.

Replace the hose if damaged.

xx1500002205

Continues on next page

Product manual - IRB 910SC 179
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
3 Secure the PCB board with cable ties.
Do not tighten the ties too tight.

xx1500002752

4 Reconnect the connectors.

• R1.BK1-2
• R1.DBP
• R2.BK1-2

CAUTION

Make sure not to mix the connectors. See

the labels on the connectors for correct
connection.

xx1500002190

A R1.BK1-2
B R1.DBP
C R2.BK1-2

5 Secure the cables with cable ties if needed.

Refitting the main cable to the base

Action Note
1 Secure the main cable package with cable
ties if needed.

Continues on next page

180 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
2 Reconnect the connectors.
• R2.MP1
• R2.ME1

xx1500002188

3 Push the main cable package into place.

xx1500002204

4 Refit the base cover with screws and

washers.

xx1500002186

Screws: M4x10 (6 pcs)

Tightening torque: 2 Nm

Concluding procedure

Action Note
1 Update the revolution counters. See Updating revolution counters on
page 351.

Continues on next page

Product manual - IRB 910SC 181
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.4 Replacing the EIB mounting plate
Continued

Action Note
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

182 Product manual - IRB 910SC

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.5 Replacing the floor cables

4.3.5 Replacing the floor cables

Location of the floor cables

The floor cables are located as shown in the figure.

xx1500002181

A Power floor cable

B Signal floor cable

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Power floor cable, 3 m 3HAC057784-001
Power floor cable, 7 m 3HAC057785-001
Power floor cable, 15 m 3HAC057786-001
Signal floor cable, 3 m 3HAC057787-001
Signal floor cable, 7 m 3HAC057788-001
Signal floor cable, 15 m 3HAC057789-001

Continues on next page

Product manual - IRB 910SC 183
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.5 Replacing the floor cables
Continued

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Required consumables
Consumable Article number Note
Cable ties -

Removing the floor cables

Use these procedures to remove the floor cables.

Preparations before removing the floor cables

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the floor cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

184 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.5 Replacing the floor cables
Continued

Action Note
2 Remove the screws and washers.

xx1500003003

3 Pull out the floor cables.

xx1500003004

Disconnecting the floor cable connectors

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

Product manual - IRB 910SC 185
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.5 Replacing the floor cables
Continued

Action Note
2 Disconnect the connectors.
• R1.EIB
• R1.MP

xx1500002202

A R1.EIB

xx1500002203

A R1.MP

Separating the signal floor cable

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

186 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.5 Replacing the floor cables
Continued

Action Note
2 Screw off the hexagonal lock nut.

xx1500003006

3 Turn the lock nut gently against the connect-

or to pull out the connector.

xx1500003007

4 Remove the signal floor cable.

xx1500003008

Refitting the floor cables

Use these procedures to refit the floor cables.

Assembling the signal floor cable

Action Note
1 Check the power floor cable.
Replace if damaged.

Continues on next page

Product manual - IRB 910SC 187
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.5 Replacing the floor cables
Continued

Action Note
2 Insert the signal floor cable.

xx1500003009

3 Turn the hexagonal lock nut gently against

the connector to enable the connector to
move through the lock nut.

xx1500003007

Lock nut: M16

4 Secure the signal floor cable with the lock
nut.

xx1500003006

Tightening torque: 20 Nm

Continues on next page

188 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.5 Replacing the floor cables
Continued

Reconnecting the floor cable connectors

Action Note
1 Reconnect the connectors.
• R1.EIB
• R1.MP

xx1500002202

A R1.EIB

xx1500002203

A R1.MP

Continues on next page

Product manual - IRB 910SC 189
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.5 Replacing the floor cables
Continued

Refitting the floor cables

Action Note
1 Push the floor cables into place.

xx1500003005

2 Secure with screws and washers.

xx1500003003

Screw: M4x10 (4 pcs)

Tightening torque: 2 Nm

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

190 Product manual - IRB 910SC

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.6 Replacing the brake release harness

4.3.6 Replacing the brake release harness

Location of the brake release harness

The brake release harness is located as shown in the figure.

xx1800001421

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Brake release harness 3HAC038361-001 Includes brake release button
and harness.

Required tools and equipment

Equipment, etc. Article number Note

Standard toolkit - Content is defined in section Standard
toolkit on page 386.
Trolley -

Continues on next page

Product manual - IRB 910SC 191
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.6 Replacing the brake release harness
Continued

Removing the brake release harness

Preparations before removing the brake release harness

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the brake release harness

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the dome nuts and washers.

xx1500002182

Continues on next page

192 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.6 Replacing the brake release harness
Continued

Action Note
3 Carefully open the user interface plate and
pull out the cable package.

CAUTION

Do not pull out the plate completely.

xx1500002183

4 Disconnect the brake release harness

connector.
• R2.BR

Tip

Take photos of the connector and cable

position before disconnection, to have as
a reference when reconnecting.

5 Remove the nut.

xx1800001422

6 Carefully pull the brake release button out.

xx1800001423

Continues on next page

Product manual - IRB 910SC 193
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.3.6 Replacing the brake release harness
Continued

Refitting the brake release harness

Refitting the brake release harness

Action Note
1 Gently push and pull the brake release
harness through the mounting hole.

CAUTION

Be careful not to bend or break the cables.

xx1800001423

2 Refit the nut.

xx1800001422

3 Connect the brake release harness connect-

or.
• R2.BR
4 Push the main cable package into place.

xx1500002207

Continues on next page

194 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.3.6 Replacing the brake release harness
Continued

Action Note
5 Refit the user interface plate.

xx1500002182

Dome nut: M4 (6 pcs)

Tightening torque: 2 Nm
Washer, 6 pcs

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

Product manual - IRB 910SC 195

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.1 Replacing the upper arm

4.4 Upper arm

4.4.1 Replacing the upper arm

Location of the upper arm

The upper arm is located as shown in the figure.

xx1500002209

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Upper arm body 3HAC057711-001
Upper cover unit 3HAC057615-001 Includes upper cover and cover
flange.
Lower cover 3HAC060106-001 Replace if damaged.
Plate for upper arm cable harness 3HAC056086-001 Replace if damaged.
Axis-4 housing with idler 3HAC056121-001 Replace if damaged.
Axis-3 drive unit housing 3HAC055184-001 Replace if damaged.
Adjusting block for axis-3 timing 3HAC056650-001 Replace if damaged.
belt

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Spare part Article number Note

Adjusting block for upper axis-4 3HAC056651-001 Replace if damaged.
timing belt
Adjusting block for lower axis-4 3HAC056652-001 Replace if damaged.
timing belt
Plain washer 3HAC056937-001 Replace if damaged.
Axis-2 mechanical stop block 3HAC055185-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - The content is defined in the section
Standard toolkit on page 386.
Sonic tensiometer - Used for measuring the timing belt
tension.
Dynamometer - Used for measuring the timing belt
tension.

Required consumables
Consumable Article number Note
Grease - THK AFA
Used for lubricating the ball screw
spline shaft.
Cable ties -

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Removing the upper arm

Use these procedures to remove the upper arm from the lower arm.

Preparations before removing the upper arm

Action Note
1 Jog axis 2 to access the cover screws.

xx1500002520

xx1500002782

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Removing the main cable package from the upper arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the dome nuts and washers.

xx1500002182

3 Carefully open the user interface plate and

pull out the cable package.

CAUTION

The plate cannot be removed completely

until the connectors are disconnected, as
shown in the following step.

xx1500002183

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
4 Disconnect the connectors:
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

Tip

Take photos of the connectors and cable xx1500002184

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002185

Removing the upper cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the robot is well

secured and that the upper arm is suppor-
ted during the removal work.

3 Remove the screws.

xx1500002220

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
4
WARNING

The cover may be damaged due to improp-

er shift. Keep the cover in position while
removing the screws.

5 Lift out the upper cover carefully.

xx1500002221

Removing the lower stop block

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the lower stop block of ball screw

spline unit to replace:
• lower cover of the upper arm
• ball screw spine unit
• upper arm body
3 Remove the screws.

xx1500002222

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
4 Remove the stop block.

xx1500002223

Removing the lower cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws.

xx1500002785

3 Remove the cover.

Tip

If only working with lower axis-4 timing belt,

no need to remove the stop block of ball
screw spline unit before removing the lower
cover.

xx1500002225

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Removing the drive unit cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Cut the cable ties.

Be careful not to damage the cabling.

Tip

Take photos of the cable position before

removing them, to have as a reference
when refitting.

xx1500002226

Removing the cable harness plate

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws and washers.

3 Remove the cable harness plate.

xx1500002228

Removing the axis-3 timing belt

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

3 Loosen the screws and move the axis-3

drive unit upwards to slacken the timing
belt.

xx1500002229

4 Remove the timing belt.

xx1500002230

Removing the lower axis-4 timing belt

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
3 Loosen the screws and move the axis-4
housing sideways to slacken the lower ax-
is-4 timing belt.

xx1500002231

4 Remove the timing belt.

xx1500002232

Removing the ball screw spline

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws.

xx1500002788

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
3 Remove the ball screw spline unit.

xx1500002787

Removing the axis-4 drive unit and upper timing belt

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

3 Loosen the screws and move the axis-4

drive unit upwards to slacken the upper
axis-4 timing belt.

xx1500002233

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
4 Remove the drive unit and timing belt.

xx1500002234

Removing the axis-4 housing with idler

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

There is a risk of tipping during the remov-

al. Make sure the gravity center is well
supported.

3 Remove the axis-4 housing with idler.

xx1500002235

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
4 Remove the adjusting blocks.

xx1500002236

xx1500002237

Removing the axis-3 housing and axis-3 drive unit

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

3 Remove the screws and washers.

xx1500002810

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
4 Lift out the axis-3 housing and drive unit.

xx1500002238

5 Cut the cable tie.

Be careful not to damage the cabling.

xx1500002815

6 Remove the screws.

WARNING

Do not remove the other screws. They hold

the gearbox together. Removing them can
damage the gearbox severely.

xx1500002797

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
7 Lift out the axis-3 drive unit carefully.

xx1500002239

Removing the axis-3 timing belt adjusting block

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the adjusting block.

xx1500002240

Removing the upper arm body

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
2
WARNING

The upper arm body with the axis-2 drive

unit weights 7 kg. Make sure the weight of
the upper arm body is properly supported,
or it may drop when it is released from the
lower arm.

3 Remove the screws and washers.

WARNING

Keep the twelve screws in the outer circle

fitted. They hold the axis-2 motor flange on
the lower arm.

xx1500002241

xx1500002242

4 Remove the upper arm body and lay it

aside on a workbench.

xx1500002799

Removing the axis-2 drive unit

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
2
WARNING

There is a risk of tipping during the remov-

al. Make sure the gravity center is well
supported.

3 Remove the screws.

WARNING

Do not remove the other screws. They hold

the gearbox together. Removing them can
damage the gearbox severely.

xx1500002800

4 Lift out the drive unit.

xx1500002243

5
Tip

If the drive unit is hard to remove, insert

two M3 screws and press out the drive unit.

xx1500002244

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Removing the axis-2 mechanical stop block

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the axis-2 mechanical stop block.

xx1500003062

See Replacing the axis-2 mechanical stop

on page 271.

Refitting the upper arm

Use these procedures to refit the upper arm.

Refitting axis-2 mechanical stop block

Action Note
1 Refit the axis-2 mechanical stop block with
screws.

xx1500003062

See Replacing the axis-2 mechanical stop

on page 271.

Refitting the axis-2 drive unit

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
2 Refit the drive unit. Axis-2 drive unit: 3HAC056153-001

CAUTION

Do not mix axis-1 and axis-2 drive units.

Always check the mark or label on the drive
units before refitting.

Note

Make sure to refit the drive unit with the

motor connectors pointing to the ball screw
spline unit location.
xx1500003068

3 Secure with screws and washers.

xx1500002800

Screw: M4x25 (12 pcs)

Tightening torque: 4.5 Nm
Washer: 4.3x9x1 (12 pcs)

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Refitting the axis-3 timing belt adjusting block

Action Note
1 Refit the adjusting block. Adjusting block: 3HAC056651-001

xx1500002240

Screw: M4x16 (2 pcs)

Tightening torque: 4.5 Nm

Refitting the axis-3 housing and axis-3 drive unit

Action Note
1 Refit the drive unit with one cabling coming Axis-3 drive unit: 3HAC056111-001
out from the upside and the other coming Axis-3 drive unit housing: 3HAC055184-
out from the downside. 001

Note

Make sure to refit the drive unit correctly

oriented with the lugs of the drive unit
bracket as a reference.

2 Secure the upper cabling with a cable tie.

Do not tighten the tie too tight.

xx1500002815

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
3 Refit drive unit screws and washers just
enough to still be able to move the drive
unit.

xx1500002797

Screw: M4x20 (3 pcs)

Tightening torque: 4.5 Nm
Washer (3HAC056937-001, 3 pcs)

Note

Only use specified washers, never replace

them with other washers.

4 Refit the housing with drive unit.

xx1500002798

Screw: M4x40 (4 pcs)

Tightening torque: 3.5 Nm
Washer: M4 (4 pcs)

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Refitting the axis-4 housing with idler

Action Note
1 Refit the adjusting blocks. Adjusting block for upper timing belt:
3HAC056651-001

xx1500002236

Screw: M3x20 (2 pcs)

Adjusting block for lower timing belt:
3HAC056652-001

xx1500002237

Screw: M4x16 (2 pcs)

Tightening torque: 4.5 Nm
2 Refit the housing with idler and fasten the
screws and washers just enough to still be
able to move the housing sideways.

xx1500002235

Screw: M4x20 (4 pcs)

Washer (3HAC056937-001, 4 pcs)

Note

Only use specified washers, never replace

them with other washers.

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Refitting the axis-4 drive unit and upper timing belt

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.
2 Place the timing belt. Axis-4 drive unit: 3HAC056112-001
Upper axis-4 timing belt: 3HAC055206-001

xx1500002801

3 Refit the drive unit and timing belt.

Note

Make sure to refit the drive unit with motor

connectors pointing against axis-3 drive
unit.

xx1500002802

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
4 Refit screws and washers just enough to
still be able to move the drive unit upwards.

xx1500002803

Screw: M4x16 (3 pcs)

Washer (3HAC056937-001, 3 pcs)

Note

Only use specified washers, never replace

them with other washers.

5 Fasten the screws little by little while using

a dynamometer to measure the belt tension
until a proper belt tension is achieved.

xx1500002233

Belt tension: F = 37 N (Recommended)

Belt tension range:
24.1 N to 27.6 N (for used timing belt, which
has been installed and used for more than
24 hours)
34.5 N to 37.9 N (for new timing belt)

Refitting the ball screw spline unit

Action Note
1 Make sure that: See Lubricating the ball screw spline unit
• all assembly surfaces are clean and on page 111.
undamaged.
• the ball screw spline unit is well-
lubricated and undamaged.
2 If a new ball screw spline unit is used, re- See "Removing the lower stop block" in
move the lower stop block to enable fitting Removing the ball screw spline unit on
of the lower cover. page 231.

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
3 Check the upper stop block of the ball Upper axis-3 and axis-4 mechanical stop
screw spline unit. block: 3HAC061259-001
Replace if damaged.
Make sure the upper surfaces of the shaft
and stop block are at the same level.

xx1600002115

4 Refit the ball screw spline unit. Ball screw spline unit: 3HAC056148-001

xx1500002787

5 Secure with screws and washers.

xx1500002788

Screw: M4x16 (6 pcs)

Tightening torque: 4.5 Nm
Washer: M4 (6 pcs)

Refitting the lower axis-4 timing belt

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
2 Refit lower axis-4 timing belt. Ensure that Lower axis-4 timing belt: 3HAC055201-001
the belt runs correctly in the grooves.

xx1500002786

3 Fasten the screws little by little while using

a dynamometer to measure the belt tension
until a proper belt tension is achieved.

xx1500002231

Belt tension: F = 101 N (Recommended)

Belt tension range:
64.5 N to 73.7 N (for used timing belt, which
has been installed and used for more than
24 hours)
92.2 N to 101 N (for new timing belt)

Refitting the axis-3 timing belt

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.
2 Refit axis-3 timing belt. Ensure that the belt Axis-3 timing belt: 3HAC055209-001
runs correctly in the grooves.

xx1500002789

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
3 Fasten the screws little by little while using
a dynamometer to measure the belt tension
until a proper belt tension is achieved.

xx1500002229

Belt tension: F = 34 N (Recommended)

Belt tension range:
21.8 N to 24.9 N (for used timing belt, which
has been installed and used for more than
24 hours)
31.1 to 34.2 N (for new timing belt)

Refitting the cable harness plate

Action Note
1 Refit the cable harness plate.
2 Secure with screws and washers.

xx1500002228

Screw: M3x8 (4 pcs)

Tightening torque: 1.5 Nm
Washer: M3 (4 pcs)

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Securing the drive unit cables

Action Note
1 Put the drive unit cables in place.

xx1500003063

A R2.ME3
B R2.MP2
C R2.MP3
D R2.MP4
E R2.ME2
F R2. ME4

2 Secure the cables with cable ties.

Do not tighten the ties too tight.

xx1500002226

Refitting the upper cover

Action Note
1 Carefully put down the upper cover, avoid- Upper cover unit: 3HAC057615-001
ing any collision to the ball screw spline
unit and drive units.

xx1500002221

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
2
Tip

Some of the screws are accessed from

below. Make sure that the robot is properly
fastened and hang out the upper arm from
the workbench to access them.

3 Refit the cover.

xx1500002220

Screw: M4x16 (6 pcs)

Tightening torque: 2 Nm

Refitting the lower cover

Action Note
1 Refit the cover. Lower cover: 3HAC060106-001

xx1500002225

2 Secure with screws.

xx1500002785

Screw: M4x8 (4 pcs)

Tightening torque: 2 Nm

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Refitting the lower stop block

Action Note
1 Check the lower stop block of the ball Lower axis-3 and axis-4 mechanical stop
screw spline unit. block: 3HAC055208-001
Replace if damaged.
2 Refit the lower stop block.
Make the notch point to the calibration
block and 90° away from the flat mark on
the shaft.
Make sure the distance between the lower
surfaces of stop block and shaft is 30 mm.

xx1500002908

A Flat mark on the shaft

B Notch
C Calibration block

xx1500002224

3 Secure with the screw.

xx1500002222

Screw: M5x8 (1 pcs)

Tightening torque: 10 Nm

Note

Only use specified screws, never replace

them with other screws.

Continues on next page

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4 Repair
4.4.1 Replacing the upper arm
Continued

Refitting the upper arm

Note

Two persons working together are required to perform this procedure.

Action Note
1
Note

Two persons working together are required

to perform this step.
Person 1: Hold the upper arm.
Person 2: Refit the screws that fasten the
upper arm to the lower arm.

2 Make sure the lower arm is secured. Lower

the upper arm down onto the right place of
the lower arm.
3 Refit the upper arm screws and washers.

xx1500002256

Screw: M4x20 (16 pcs)

Tightening torque: 4.5 Nm
Washer: 4.3x9x1.3 (16 pcs)

Refitting the main cable to the upper arm

Action Note
1 Secure the main cable package with cable
ties if needed.

Continues on next page

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 4 Repair
4.4.1 Replacing the upper arm
Continued

Action Note
2 Reconnect the connectors.
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

xx1500002184

xx1500002185

3 Push the main cable package into place.

xx1500002207

4 Refit the user interface plate.

xx1500002182

Dome nut: M4 (6 pcs)

Tightening torque: 2 Nm
Washer, 6 pcs

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.1 Replacing the upper arm
Continued

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

228 Product manual - IRB 910SC

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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing the ball screw spline unit

4.4.2 Replacing the ball screw spline unit

General

Note

If a collision with the stop blocks on the ball screw spline unit occur, check and
retighten all screws before replacement work. Replace damaged or cracked
screws.

Location of the ball screw spline unit

The ball screw spline unit is located as shown in the figure.

xx1500002212

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Ball screw spline unit 3HAC056148-001

Continues on next page

Product manual - IRB 910SC 229
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Required tools and equipment

Equipment Article number Note

Standard toolkit - The content is defined in the section
Standard toolkit on page 386.
Sonic tensiometer - Used for measuring the timing belt
tension.
Dynamometer - Used for measuring the timing belt
tension.

Required consumables
Consumable Article number Note
Grease - THK AFA
Used for lubricating the ball screw
spline shaft.
Cable ties -

Continues on next page

230 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Removing the ball screw spline unit

Use these procedures to remove the ball screw spline unit.

Preparations before removing the ball screw spline unit

Action Note
1 Jog axis 2 to access the cover screws.

xx1500002520

xx1500002782

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

Product manual - IRB 910SC 231
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Removing the main cable package from the upper arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the dome nuts and washers.

xx1500002182

3 Carefully open the user interface plate and

pull out the cable package.

CAUTION

The plate cannot be removed completely

until the connectors are disconnected, as
shown in the following step.

xx1500002183

Continues on next page

232 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Action Note
4 Disconnect the connectors:
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

Tip

Take photos of the connectors and cable xx1500002184

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002185

Removing the upper cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the robot is well

secured and that the upper arm is suppor-
ted during the removal work.

3 Remove the screws.

xx1500002220

Continues on next page

Product manual - IRB 910SC 233
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Action Note
4
WARNING

The cover may be damaged due to improp-

er shift. Keep the cover in position while
removing the screws.

5 Lift out the upper cover carefully.

xx1500002221

Removing the lower stop block

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the lower stop block of ball screw

spline unit to replace:
• lower cover of the upper arm
• ball screw spine unit
• upper arm body
3 Remove the screws.

xx1500002222

Continues on next page

234 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Action Note
4 Remove the stop block.

xx1500002223

Removing the lower cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws.

xx1500002785

3 Remove the cover.

Tip

If only working with lower axis-4 timing belt,

no need to remove the stop block of ball
screw spline unit before removing the lower
cover.

xx1500002225

Continues on next page

Product manual - IRB 910SC 235
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Removing the axis-3 timing belt

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

3 Loosen the screws and move the axis-3

drive unit upwards to slacken the timing
belt.

xx1500002229

4 Remove the timing belt.

xx1500002230

Removing the lower axis-4 timing belt

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

Continues on next page

236 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Action Note
3 Loosen the screws and move the axis-4
housing sideways to slacken the lower ax-
is-4 timing belt.

xx1500002231

4 Remove the timing belt.

xx1500002232

Removing the ball screw spline

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws.

xx1500002788

Continues on next page

Product manual - IRB 910SC 237
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Action Note
3 Remove the ball screw spline unit.

xx1500002787

Refitting the ball screw spline unit

Use these procedures to refit the ball screw spline unit.

Refitting the ball screw spline unit

Action Note
1 Make sure that: See Lubricating the ball screw spline unit
• all assembly surfaces are clean and on page 111.
undamaged.
• the ball screw spline unit is well-
lubricated and undamaged.
2 If a new ball screw spline unit is used, re- See "Removing the lower stop block" in
move the lower stop block to enable fitting Removing the ball screw spline unit on
of the lower cover. page 231.
3 Check the upper stop block of the ball Upper axis-3 and axis-4 mechanical stop
screw spline unit. block: 3HAC061259-001
Replace if damaged.
Make sure the upper surfaces of the shaft
and stop block are at the same level.

xx1600002115

Continues on next page

238 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Action Note
4 Refit the ball screw spline unit. Ball screw spline unit: 3HAC056148-001

xx1500002787

5 Secure with screws and washers.

xx1500002788

Screw: M4x16 (6 pcs)

Tightening torque: 4.5 Nm
Washer: M4 (6 pcs)

Refitting the lower axis-4 timing belt

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.
2 Refit lower axis-4 timing belt. Ensure that Lower axis-4 timing belt: 3HAC055201-001
the belt runs correctly in the grooves.

xx1500002786

Continues on next page

Product manual - IRB 910SC 239
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Action Note
3 Fasten the screws little by little while using
a dynamometer to measure the belt tension
until a proper belt tension is achieved.

xx1500002231

Belt tension: F = 101 N (Recommended)

Belt tension range:
64.5 N to 73.7 N (for used timing belt, which
has been installed and used for more than
24 hours)
92.2 N to 101 N (for new timing belt)

Refitting the axis-3 timing belt

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.
2 Refit axis-3 timing belt. Ensure that the belt Axis-3 timing belt: 3HAC055209-001
runs correctly in the grooves.

xx1500002789

Continues on next page

240 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Action Note
3 Fasten the screws little by little while using
a dynamometer to measure the belt tension
until a proper belt tension is achieved.

xx1500002229

Belt tension: F = 34 N (Recommended)

Belt tension range:
21.8 N to 24.9 N (for used timing belt, which
has been installed and used for more than
24 hours)
31.1 to 34.2 N (for new timing belt)

Refitting the upper cover

Action Note
1 Carefully put down the upper cover, avoid- Upper cover unit: 3HAC057615-001
ing any collision to the ball screw spline
unit and drive units.

xx1500002221

2
Tip

Some of the screws are accessed from

below. Make sure that the robot is properly
fastened and hang out the upper arm from
the workbench to access them.

Continues on next page

Product manual - IRB 910SC 241
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Action Note
3 Refit the cover.

xx1500002220

Screw: M4x16 (6 pcs)

Tightening torque: 2 Nm

Refitting the lower cover

Action Note
1 Refit the cover. Lower cover: 3HAC060106-001

xx1500002225

2 Secure with screws.

xx1500002785

Screw: M4x8 (4 pcs)

Tightening torque: 2 Nm

Refitting the lower stop block

Action Note
1 Check the lower stop block of the ball Lower axis-3 and axis-4 mechanical stop
screw spline unit. block: 3HAC055208-001
Replace if damaged.

Continues on next page

242 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Action Note
2 Refit the lower stop block.
Make the notch point to the calibration
block and 90° away from the flat mark on
the shaft.
Make sure the distance between the lower
surfaces of stop block and shaft is 30 mm.

xx1500002908

A Flat mark on the shaft

B Notch
C Calibration block

xx1500002224

3 Secure with the screw.

xx1500002222

Screw: M5x8 (1 pcs)

Tightening torque: 10 Nm

Note

Only use specified screws, never replace

them with other screws.

Refitting the main cable to the upper arm

Action Note
1 Secure the main cable package with cable
ties if needed.

Continues on next page

Product manual - IRB 910SC 243
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Action Note
2 Reconnect the connectors.
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

xx1500002184

xx1500002185

3 Push the main cable package into place.

xx1500002207

4 Refit the user interface plate.

xx1500002182

Dome nut: M4 (6 pcs)

Tightening torque: 2 Nm
Washer, 6 pcs

Continues on next page

244 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.2 Replacing the ball screw spline unit
Continued

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

Product manual - IRB 910SC 245

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.3 Replacing the axis-3 timing belt

4.4.3 Replacing the axis-3 timing belt

Location of the axis-3 timing belt

The axis-3 timing belt is located as shown in the figure.

xx1500002218

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Axis-3 timing belt 3HAC055209-001
Upper cover unit 3HAC057615-001 Includes upper cover and cover
flange.

Required tools and equipment

Note

The spare part numbers that are listed in the table can be out of date. See the
latest revision of Product manual, spare parts - IRB 910SC on ABB Library.

Continues on next page

246 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.3 Replacing the axis-3 timing belt
Continued

Equipment Article number Note

Standard toolkit - The content is defined in the section
Standard toolkit on page 386.
Sonic tensiometer - Used for measuring the timing belt
tension.
Dynamometer - Used for measuring the timing belt
tension.

Required consumables
Consumable Article number Note
Cable ties -

Removing the axis-3 timing belt

Use these procedures to remove the axis-3 timing belt.

Preparations before removing the axis-3 timing belt

Action Note
1 Jog axis 2 to access the cover screws.

xx1500002520

xx1500002782

Continues on next page

Product manual - IRB 910SC 247
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.3 Replacing the axis-3 timing belt
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the main cable package from the upper arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the dome nuts and washers.

xx1500002182

3 Carefully open the user interface plate and

pull out the cable package.

CAUTION

The plate cannot be removed completely

until the connectors are disconnected, as
shown in the following step.

xx1500002183

Continues on next page

248 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.3 Replacing the axis-3 timing belt
Continued

Action Note
4 Disconnect the connectors:
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

Tip

Take photos of the connectors and cable xx1500002184

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002185

Removing the upper cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the robot is well

secured and that the upper arm is suppor-
ted during the removal work.

3 Remove the screws.

xx1500002220

Continues on next page

Product manual - IRB 910SC 249
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.3 Replacing the axis-3 timing belt
Continued

Action Note
4
WARNING

The cover may be damaged due to improp-

er shift. Keep the cover in position while
removing the screws.

5 Lift out the upper cover carefully.

xx1500002221

Removing the drive unit cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Cut the cable ties.

Be careful not to damage the cabling.

Tip

Take photos of the cable position before

removing them, to have as a reference
when refitting.

xx1500002226

Removing the axis-3 timing belt

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

250 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.3 Replacing the axis-3 timing belt
Continued

Action Note
2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

3 Loosen the screws and move the axis-3

drive unit upwards to slacken the timing
belt.

xx1500002229

4 Remove the timing belt.

xx1500002230

Refitting the axis-3 timing belt

Use these procedures to refit the axis-3 timing belt.

Refitting the axis-3 timing belt

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.

Continues on next page

Product manual - IRB 910SC 251
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.3 Replacing the axis-3 timing belt
Continued

Action Note
2 Refit axis-3 timing belt. Ensure that the belt Axis-3 timing belt: 3HAC055209-001
runs correctly in the grooves.

xx1500002789

3 Fasten the screws little by little while using

a dynamometer to measure the belt tension
until a proper belt tension is achieved.

xx1500002229

Belt tension: F = 34 N (Recommended)

Belt tension range:
21.8 N to 24.9 N (for used timing belt, which
has been installed and used for more than
24 hours)
31.1 to 34.2 N (for new timing belt)

Continues on next page

252 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.3 Replacing the axis-3 timing belt
Continued

Securing the drive unit cables

Action Note
1 Put the drive unit cables in place.

xx1500003063

A R2.ME3
B R2.MP2
C R2.MP3
D R2.MP4
E R2.ME2
F R2. ME4

2 Secure the cables with cable ties.

Do not tighten the ties too tight.

xx1500002226

Refitting the upper cover

Action Note
1 Carefully put down the upper cover, avoid- Upper cover unit: 3HAC057615-001
ing any collision to the ball screw spline
unit and drive units.

xx1500002221

Continues on next page

Product manual - IRB 910SC 253
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.3 Replacing the axis-3 timing belt
Continued

Action Note
2
Tip

Some of the screws are accessed from

below. Make sure that the robot is properly
fastened and hang out the upper arm from
the workbench to access them.

3 Refit the cover.

xx1500002220

Screw: M4x16 (6 pcs)

Tightening torque: 2 Nm

Refitting the main cable to the upper arm

Action Note
1 Secure the main cable package with cable
ties if needed.
2 Reconnect the connectors.
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

xx1500002184

xx1500002185

Continues on next page

254 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.3 Replacing the axis-3 timing belt
Continued

Action Note
3 Push the main cable package into place.

xx1500002207

4 Refit the user interface plate.

xx1500002182

Dome nut: M4 (6 pcs)

Tightening torque: 2 Nm
Washer, 6 pcs

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

Product manual - IRB 910SC 255

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.4 Replacing the axis-4 timing belts

4.4.4 Replacing the axis-4 timing belts

Location of the axis-4 timing belts

The axis-4 timing belts are located as shown in the figures.

xx1500002216

xx1500002217

Continues on next page

256 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Upper axis-4 timing belt 3HAC055206-001
Lower axis-4 timing belt 3HAC055201-001
Upper cover unit 3HAC057615-001 Includes upper cover and cover
flange.
Plain washer 3HAC056937-001 Replace if damaged.

Required tools and equipment

Note

The spare part numbers that are listed in the table can be out of date. See the
latest revision of Product manual, spare parts - IRB 910SC on ABB Library.

Equipment Article number Note

Standard toolkit - The content is defined in the section
Standard toolkit on page 386.
Sonic tensiometer - Used for measuring the timing belt
tension.
Dynamometer - Used for measuring the timing belt
tension.

Required consumables
Consumable Article number Note
Cable ties -

Continues on next page

Product manual - IRB 910SC 257
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Removing the axis-4 timing belts

Use these procedures to remove the axis-4 timing belts.

Preparations before removing the axis-4 timing belts

Action Note
1 Jog axis 2 to access the cover screws.

xx1500002520

xx1500002782

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Continues on next page

258 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Removing the main cable package from the upper arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the dome nuts and washers.

xx1500002182

3 Carefully open the user interface plate and

pull out the cable package.

CAUTION

The plate cannot be removed completely

until the connectors are disconnected, as
shown in the following step.

xx1500002183

Continues on next page

Product manual - IRB 910SC 259
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Action Note
4 Disconnect the connectors:
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

Tip

Take photos of the connectors and cable xx1500002184

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002185

Removing the upper cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the robot is well

secured and that the upper arm is suppor-
ted during the removal work.

3 Remove the screws.

xx1500002220

Continues on next page

260 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Action Note
4
WARNING

The cover may be damaged due to improp-

er shift. Keep the cover in position while
removing the screws.

5 Lift out the upper cover carefully.

xx1500002221

Removing the drive unit cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Cut the cable ties.

Be careful not to damage the cabling.

Tip

Take photos of the cable position before

removing them, to have as a reference
when refitting.

xx1500002226

Removing the lower cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

Product manual - IRB 910SC 261
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Action Note
2 Remove the screws.

xx1500002785

3 Remove the cover.

Tip

If only working with lower axis-4 timing belt,

no need to remove the stop block of ball
screw spline unit before removing the lower
cover.

xx1500002225

Removing the lower axis-4 timing belt

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

3 Loosen the screws and move the axis-4

housing sideways to slacken the lower ax-
is-4 timing belt.

xx1500002231

Continues on next page

262 Product manual - IRB 910SC
3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Action Note
4 Remove the timing belt.

xx1500002232

Removing the axis-4 drive unit and upper timing belt

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

3 Loosen the screws and move the axis-4

drive unit upwards to slacken the upper
axis-4 timing belt.

xx1500002233

Continues on next page

Product manual - IRB 910SC 263
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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Action Note
4 Remove the drive unit and timing belt.

xx1500002234

Refitting the axis-4 timing belts

Use these procedures to refit the axis-4 timing belts.

Refitting the axis-4 drive unit and upper timing belt

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.
2 Place the timing belt. Axis-4 drive unit: 3HAC056112-001
Upper axis-4 timing belt: 3HAC055206-001

xx1500002801

Continues on next page

264 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Action Note
3 Refit the drive unit and timing belt.

Note

Make sure to refit the drive unit with motor

connectors pointing against axis-3 drive
unit.

xx1500002802

4 Refit screws and washers just enough to

still be able to move the drive unit upwards.

xx1500002803

Screw: M4x16 (3 pcs)

Washer (3HAC056937-001, 3 pcs)

Note

Only use specified washers, never replace

them with other washers.

5 Fasten the screws little by little while using

a dynamometer to measure the belt tension
until a proper belt tension is achieved.

xx1500002233

Belt tension: F = 37 N (Recommended)

Belt tension range:
24.1 N to 27.6 N (for used timing belt, which
has been installed and used for more than
24 hours)
34.5 N to 37.9 N (for new timing belt)

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Refitting the lower axis-4 timing belt

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.
2 Refit lower axis-4 timing belt. Ensure that Lower axis-4 timing belt: 3HAC055201-001
the belt runs correctly in the grooves.

xx1500002786

3 Fasten the screws little by little while using

a dynamometer to measure the belt tension
until a proper belt tension is achieved.

xx1500002231

Belt tension: F = 101 N (Recommended)

Belt tension range:
64.5 N to 73.7 N (for used timing belt, which
has been installed and used for more than
24 hours)
92.2 N to 101 N (for new timing belt)

Refitting the lower cover

Action Note
1 Refit the cover. Lower cover: 3HAC060106-001

xx1500002225

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Action Note
2 Secure with screws.

xx1500002785

Screw: M4x8 (4 pcs)

Tightening torque: 2 Nm

Securing the drive unit cables

Action Note
1 Put the drive unit cables in place.

xx1500003063

A R2.ME3
B R2.MP2
C R2.MP3
D R2.MP4
E R2.ME2
F R2. ME4

2 Secure the cables with cable ties.

Do not tighten the ties too tight.

xx1500002226

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Refitting the upper cover

Action Note
1 Carefully put down the upper cover, avoid- Upper cover unit: 3HAC057615-001
ing any collision to the ball screw spline
unit and drive units.

xx1500002221

2
Tip

Some of the screws are accessed from

below. Make sure that the robot is properly
fastened and hang out the upper arm from
the workbench to access them.

3 Refit the cover.

xx1500002220

Screw: M4x16 (6 pcs)

Tightening torque: 2 Nm

Refitting the main cable to the upper arm

Action Note
1 Secure the main cable package with cable
ties if needed.

Continues on next page

268 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Action Note
2 Reconnect the connectors.
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

xx1500002184

xx1500002185

3 Push the main cable package into place.

xx1500002207

4 Refit the user interface plate.

xx1500002182

Dome nut: M4 (6 pcs)

Tightening torque: 2 Nm
Washer, 6 pcs

Continues on next page

Product manual - IRB 910SC 269
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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.4 Replacing the axis-4 timing belts
Continued

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

270 Product manual - IRB 910SC

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.5 Replacing the axis-2 mechanical stop

4.4.5 Replacing the axis-2 mechanical stop

General

Note

If a collision with the mechanical stops occur, check and retighten all screws
before any installation or service work. Replace damaged or cracked screws.

Location of the axis-2 mechanical stop

The axis-2 mechanical stop is located as shown in the figure.
Axis-2 mechanical stop block Axis-2 mechanical stop rubber

xx1500002175 xx1500002174

3HAC055185-001 3HAC056017-001

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Axis-2 mechanical stop rubber 3HAC056017-001 Replace if damaged.
Axis-2 mechanical stop block 3HAC055185-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Required consumables
Consumable Article number Note
Locking liquid 3HAB7116-1 Loctite 243

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.5 Replacing the axis-2 mechanical stop
Continued

Replacing the axis-2 mechanical stop

Use these procedures to replace the axis-2 mechanical stop.

Preparations before replacing the axis-2 mechanical stop

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Replacing the axis-2 mechanical stop block

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

272 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.5 Replacing the axis-2 mechanical stop
Continued

Action Note
2 Remove the block by removing the screws.
3 Refit and secure the new mechanical stop
block.

Tip

One more mechanical stop block can be

fitted to restrict the working range of axis
2, as shown in the following figure.
The block and related screws are provided
in accessory package. xx1500002245

Screw: M5x15 (2 pcs)

Tightening torque: 5 Nm

xx1500003065

Replacing the axis-2 mechanical stop rubbers

Note

Two persons working together are required to perform this procedure.

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

The upper arm weights 13.2 kg. It may drop

by the force of gravity when it is released
from the lower arm. Make sure the weight
of the upper arm body is properly suppor-
ted.

3
Note

Two persons working together are required

to perform this step.
Person 1: Hold the upper arm.
Person 2: Remove the screws that fasten
the upper arm to the lower arm.

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.4.5 Replacing the axis-2 mechanical stop
Continued

Action Note
4 Remove the screws and washers.

WARNING

Keep the twelve screws in the outer circle

fitted. They hold the axis-2 motor flange on
the lower arm.

xx1500002256

xx1500002257

5 Remove the upper arm and lay it on a

workbench.
6 Remove the rubbers by removing the
screws.
7 Refit and secure the new mechanical stop
rubbers with screws.
Lock screws with locking liquid (Loctite
243).

xx1500002246

Screw: M3x6 (2 pcs)

Tightening torque: 0.3 Nm
8 Make sure the lower arm is secured. Lower
the upper arm down onto the right place of
the lower arm.
9 Refit the upper arm screws and washers.

xx1500002256

Screw: M4x20 (16 pcs)

Tightening torque: 4.5 Nm

Continues on next page

274 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.4.5 Replacing the axis-2 mechanical stop
Continued

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

Product manual - IRB 910SC 275

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the lower arm

4.5 Lower arm and base

4.5.1 Replacing the lower arm

Location of the lower arm

The lower arm is located as shown in the figure.

xx1500002210

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Lower arm, 450 mm 3HAC057609-001 Used for IRB 910SC-3/0.45
Lower arm, 550 mm 3HAC057612-001 Used for IRB 910SC-3/0.55
Lower arm, 650 mm 3HAC057613-001 Used for IRB 910SC-3/0.65
Lower arm cover 3HAC056065-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Continues on next page

276 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.5.1 Replacing the lower arm
Continued

Required consumables
Consumable Article number Note
Cable ties -

Removing the lower arm

Use these procedures to remove the lower arm.

Preparations before removing the lower arm

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the main cable package from the upper arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

Product manual - IRB 910SC 277
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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the lower arm
Continued

Action Note
2 Remove the dome nuts and washers.

xx1500002182

3 Carefully open the user interface plate and

pull out the cable package.

CAUTION

The plate cannot be removed completely

until the connectors are disconnected, as
shown in the following step.

xx1500002183

4 Disconnect the connectors:

• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

Tip

Take photos of the connectors and cable xx1500002184

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002185

Removing the upper arm

Note

Two persons working together are required to perform this procedure.

Continues on next page
278 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.5.1 Replacing the lower arm
Continued

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

The upper arm weights 13.2 kg. It may drop

by the force of gravity when it is released
from the lower arm. Make sure the weight
of the upper arm body is properly suppor-
ted.

3
Note

Two persons working together are required

to perform this step.
Person 1: Hold the upper arm.
Person 2: Remove the screws that fasten
the upper arm to the lower arm.

4 Remove the screws and washers.

WARNING

Keep the twelve screws in the outer circle

fitted. They hold the axis-2 motor flange on
the lower arm.

xx1500002256

xx1500002257

5 Remove the upper arm and lay it aside on

a workbench.

Removing the lower arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

Product manual - IRB 910SC 279
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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the lower arm
Continued

Action Note
2 Remove the cover.

Tip

If the cover is hard to remove, fit a screw

to its attachment hole to help press out the
cover.

xx1500002259

3
WARNING

The lower arm weights 3.2 kg. It may drop

when it is released from the base. Make
sure the weight of the lower arm is properly
supported.

4 Remove the screws and washers.

5 Lay the lower arm aside on a workbench.

xx1500002260

Continues on next page

280 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.5.1 Replacing the lower arm
Continued

Refitting the lower arm

Use these procedures to refit the lower arm.

Refitting the lower arm

Action Note
1 Refit the lower arm and tighten screws. Lower arm, 450 mm: 3HAC057609-001 (For
IRB 910SC-3/0.45)
Lower arm, 550 mm: 3HAC057612-001 (For
IRB 910SC-3/0.65)
Lower arm, 650 mm: 3HAC057613-001 (For
IRB 910SC-3/0.65)

xx1500002260

Screw: M4x20 (16 pcs)

Tightening torque: 4.2 Nm
Washer: 4.3x9x1.3 (16 pcs)
2 Refit the cover. Lower arm cover: 3HAC056065-001

xx1500002259

Screw: M3x6 (3 pcs)

Tightening torque: 1 Nm

Refitting the upper arm

Note

Two persons working together are required to perform this procedure.

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the lower arm
Continued

Action Note
1
Note

Two persons working together are required

to perform this step.
Person 1: Hold the upper arm.
Person 2: Refit the screws that fasten the
upper arm to the lower arm.

2 Make sure the lower arm is secured. Lower

the upper arm down onto the right place of
the lower arm.
3 Refit the upper arm screws and washers.

xx1500002256

Screw: M4x20 (16 pcs)

Tightening torque: 4.5 Nm
Washer: 4.3x9x1.3 (16 pcs)

Refitting the main cable to the upper arm

Action Note
1 Secure the main cable package with cable
ties if needed.

Continues on next page

282 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.5.1 Replacing the lower arm
Continued

Action Note
2 Reconnect the connectors.
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

xx1500002184

xx1500002185

3 Push the main cable package into place.

xx1500002207

4 Refit the user interface plate.

xx1500002182

Dome nut: M4 (6 pcs)

Tightening torque: 2 Nm
Washer, 6 pcs

Continues on next page

Product manual - IRB 910SC 283
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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.5.1 Replacing the lower arm
Continued

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

284 Product manual - IRB 910SC

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.5.2 Replacing the base

4.5.2 Replacing the base

Location of the base

The base is located as shown in the figure.

xx1500002211

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Base 3HAC057614-001
Base bottom cover 3HAC055216-001 Replace if damaged.
Lower arm cover 3HAC056065-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.5.2 Replacing the base
Continued

Required consumables
Consumable Article number Note
Cable ties -

Removing the cabling from the base

Use these procedures to remove the cabling from the base.

Preparations before replacing the base

Action Note
1 Jog axis 2 to easily support the arm system
weight.

xx1500002804

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the main cable package from the base

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

286 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.5.2 Replacing the base
Continued

Action Note
2 Remove the screws and washers.

xx1500002186

3 Carefully open the base cover and pull out

the cable package.

CAUTION

The cover cannot be removed completely

until the connectors are disconnected.

CAUTION

Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail-
ures. xx1500002187

4 Disconnect the connectors:

• R2.MP1
• R2.ME1

Tip

Take photos of the connectors and cable

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002188

Replacing the base

Use these procedures to replace the base.

Removing the arm system

Note

Two persons working together are required to perform this procedure.

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.5.2 Replacing the base
Continued

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Remove the cover.

Tip

If the cover is hard to remove, fit a screw

to its attachment hole to help press out the
cover.

xx1500002259

3
WARNING

The arm system weights 16.4 kg.

The arm system may drop when released
from the base. Make sure the weight of the
arm system is properly supported.

4
Note

Two persons working together are required

to perform this step.
Person 1: Hold the arm system.
Person 2: Remove the screws that fasten
the arm system to the base.

5
CAUTION

Handle the main cable package with care.

Minimum bending radius is approximately
10 times of the cable diameter.

Continues on next page

288 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.5.2 Replacing the base
Continued

Action Note
6 Remove the screws and washers.

xx1500002805

7 Remove the arm system and lay it aside

on a workbench.

xx1500002261

Removing the axis-1 drive unit

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.5.2 Replacing the base
Continued

Action Note
2 Remove the screws and washers.

WARNING

Do not remove the inner circle screws.

They are holding the gearbox together and
removing them may damage the gearbox
severely.

3 Pull the drive unit out carefully while pulling

the motor cables out of the base rear.

Tip

If the drive unit is hard to remove, insert

two M3 screws and press out the drive unit. xx1500002262

xx1500002263

Removing the base

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the attachment screws and wash-

ers.

xx1500002264

Continues on next page

290 Product manual - IRB 910SC
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 4 Repair
4.5.2 Replacing the base
Continued

Action Note
3 Put the base on its side.

xx1500002806

4 Remove the bottom cover.

xx1500002265

Refitting the base

Action Note
1 Refit the bottom cover. Base bottom cover: 3HAC055216-001

xx1500002265

Screw: M3x8 (6 pcs)

Tightening torque: 2 Nm

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.5.2 Replacing the base
Continued

Action Note
2 Put the base in a raised position.

xx1500002807

3 Fasten the attachment screws and wash-

ers.

xx1500002264

Attachment screws: M10x25 (4 pcs), qual-

ity: 8.8.
Washers: 20x10.5x2.
Pin: 2 pcs, D6x20, ISO 2338 - 6m6x20 - A1.
Tightening Torque: 45 Nm.

Refitting the axis-1 drive unit

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.

Continues on next page

292 Product manual - IRB 910SC
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 4 Repair
4.5.2 Replacing the base
Continued

Action Note
2 Carefully insert the complete drive unit Axis-1 drive unit: 3HAC055900-001
while pulling the motor cables out of the
base rear.

CAUTION

Do not mix axis-1 and axis-2 drive units.

Always check the mark or label on the drive
units before refitting.

3 Refit the screws and washers.

xx1500002262

Screw: M4x20 (12 pcs)

Tightening torque: 4.5 Nm
Washer: 4.3x9x1 (12 pcs)

Refitting the arm system

Note

Two persons working together are required to perform this procedure.

Action Note
1
Note

Two persons working together are required

to perform this step.
Person 1: Hold the arm system.
Person 2: Refit the screws that fasten the
arm system to the base.

2 Refit the whole arm system.

WARNING

The arm system weights 16.4 kg. Support

the gravity center properly.

xx1500002261

Screw: M4x20 (16 pcs)

Tightening torque: 4.2 Nm
Washer: 4.3x9x1.3 (16 pcs)

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.5.2 Replacing the base
Continued

Action Note
3
CAUTION

Handle the main cable package with care.

Minimum bending radius is approximately
10x the cable diameter.

4 Refit the cover. Lower arm cover: 3HAC056065-001

xx1500002259

Screw: M3x6 (3 pcs)

Tightening torque: 1 Nm

Refitting the cabling to the base

Use these procedures to refit the cabling to the base.

Refitting the main cable to the base

Action Note
1 Secure the main cable package with cable
ties if needed.
2 Reconnect the connectors.
• R2.MP1
• R2.ME1

xx1500002188

Continues on next page

294 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.5.2 Replacing the base
Continued

Action Note
3 Push the main cable package into place.

xx1500002204

4 Refit the base cover with screws and

washers.

xx1500002186

Screws: M4x10 (6 pcs)

Tightening torque: 2 Nm

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

Product manual - IRB 910SC 295

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.5.3 Replacing the axis-1 mechanical stop

4.5.3 Replacing the axis-1 mechanical stop

General

Note

If a collision with the mechanical stops occur, check and retighten all screws
before any installation or service work. Replace damaged or cracked screws.

Location of the axis-1 mechanical stop

The axis-1 mechanical stop is located as shown in the figure.
Axis-1 mechanical stop block Axis-1 mechanical stop rubber

xx1500002177 xx1500002176

3HAC055164-001 3HAC056042-001

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Axis-1 mechanical stop rubber 3HAC056042-001 Replace if damaged.
Axis-1 mechanical stop block 3HAC055164-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Required consumables
Consumable Article number Note
Locking liquid 3HAB7116-1 Loctite 243

Continues on next page

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 4 Repair
4.5.3 Replacing the axis-1 mechanical stop
Continued

Replacing the axis-1 mechanical stop

Use these procedures to replace the axis-1 mechanical stop.

Preparations before replacing the axis-1 mechanical stop

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Replacing the axis-1 mechanical stop block

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the block by removing the screws

and washers.
3 Refit and secure the new mechanical stop
block.

xx1500002247

Screw: 9ADA183-24 (M6x16, 2 pcs)

Tightening torque: 6 Nm
Washer: 9ADA312-6 (M6, 2 pcs)

Continues on next page

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4 Repair
4.5.3 Replacing the axis-1 mechanical stop
Continued

Replacing the axis-1 mechanical stop rubbers

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the rubbers by removing the

screws.

xx1500002255

3 Refit and secure the new mechanical stop Screw: M3x12 (4 pcs)
rubbers with screws. Tightening torque: 0.3 Nm
Lock screws with locking liquid (Loctite
243).

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

298 Product manual - IRB 910SC

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 4 Repair
4.6.1 Replacing the axis-1 drive unit

4.6 Drive units

4.6.1 Replacing the axis-1 drive unit

Location of the axis-1 drive unit

The axis-1 drive unit is located as shown in the figure.

xx1500002213

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Axis-1 drive unit 3HAC055900-001 Includes axis-1 gearbox, motor
and motor adapter.
Lower arm cover 3HAC056065-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Continues on next page

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4 Repair
4.6.1 Replacing the axis-1 drive unit
Continued

Required consumables
Consumable Article number Note
Cable ties -

Removing the axis-1 drive unit

Use these procedures to remove the axis-1 drive unit.

Preparations before removing the axis-1 drive unit

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the main cable package from the base

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

300 Product manual - IRB 910SC
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 4 Repair
4.6.1 Replacing the axis-1 drive unit
Continued

Action Note
2 Remove the screws and washers.

xx1500002186

3 Carefully open the base cover and pull out

the cable package.

CAUTION

The cover cannot be removed completely

until the connectors are disconnected.

CAUTION

Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail-
ures. xx1500002187

4 Disconnect the connectors:

• R2.MP1
• R2.ME1

Tip

Take photos of the connectors and cable

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002188

Removing the arm system

Note

Two persons working together are required to perform this procedure.

Continues on next page

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4 Repair
4.6.1 Replacing the axis-1 drive unit
Continued

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Remove the cover.

Tip

If the cover is hard to remove, fit a screw

to its attachment hole to help press out the
cover.

xx1500002259

3
WARNING

The arm system weights 16.4 kg.

The arm system may drop when released
from the base. Make sure the weight of the
arm system is properly supported.

4
Note

Two persons working together are required

to perform this step.
Person 1: Hold the arm system.
Person 2: Remove the screws that fasten
the arm system to the base.

5
CAUTION

Handle the main cable package with care.

Minimum bending radius is approximately
10 times of the cable diameter.

Continues on next page

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 4 Repair
4.6.1 Replacing the axis-1 drive unit
Continued

Action Note
6 Remove the screws and washers.

xx1500002805

7 Remove the arm system and lay it aside

on a workbench.

xx1500002261

Removing the axis-1 drive unit

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.6.1 Replacing the axis-1 drive unit
Continued

Action Note
2 Remove the screws and washers.

WARNING

Do not remove the inner circle screws.

They are holding the gearbox together and
removing them may damage the gearbox
severely.

3 Pull the drive unit out carefully while pulling

the motor cables out of the base rear.

Tip

If the drive unit is hard to remove, insert

two M3 screws and press out the drive unit. xx1500002262

xx1500002263

Refitting the axis-1 drive unit

Use these procedures to refit the axis-1 drive unit.

Refitting the axis-1 drive unit

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.

Continues on next page

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 4 Repair
4.6.1 Replacing the axis-1 drive unit
Continued

Action Note
2 Carefully insert the complete drive unit Axis-1 drive unit: 3HAC055900-001
while pulling the motor cables out of the
base rear.

CAUTION

Do not mix axis-1 and axis-2 drive units.

Always check the mark or label on the drive
units before refitting.

3 Refit the screws and washers.

xx1500002262

Screw: M4x20 (12 pcs)

Tightening torque: 4.5 Nm
Washer: 4.3x9x1 (12 pcs)

Refitting the arm system

Note

Two persons working together are required to perform this procedure.

Action Note
1
Note

Two persons working together are required

to perform this step.
Person 1: Hold the arm system.
Person 2: Refit the screws that fasten the
arm system to the base.

2 Refit the whole arm system.

WARNING

The arm system weights 16.4 kg. Support

the gravity center properly.

xx1500002261

Screw: M4x20 (16 pcs)

Tightening torque: 4.2 Nm
Washer: 4.3x9x1.3 (16 pcs)

Continues on next page

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4 Repair
4.6.1 Replacing the axis-1 drive unit
Continued

Action Note
3
CAUTION

Handle the main cable package with care.

Minimum bending radius is approximately
10x the cable diameter.

4 Refit the cover. Lower arm cover: 3HAC056065-001

xx1500002259

Screw: M3x6 (3 pcs)

Tightening torque: 1 Nm

Refitting the main cable to the base

Action Note
1 Secure the main cable package with cable
ties if needed.
2 Reconnect the connectors.
• R2.MP1
• R2.ME1

xx1500002188

Continues on next page

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 4 Repair
4.6.1 Replacing the axis-1 drive unit
Continued

Action Note
3 Push the main cable package into place.

xx1500002204

4 Refit the base cover with screws and

washers.

xx1500002186

Screws: M4x10 (6 pcs)

Tightening torque: 2 Nm

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

Product manual - IRB 910SC 307

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.6.2 Replacing the axis-2 drive unit

4.6.2 Replacing the axis-2 drive unit

Location of the axis-2 drive unit

The axis-2 drive unit is located as shown in the figure.

xx1500002214

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Axis-2 drive unit 3HAC056153-001 Includes axis-2 gearbox, motor
and motor adapter.
Upper cover unit 3HAC057615-001 Includes upper cover and cover
flange.
Plate for upper arm cable harness 3HAC056086-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - Content is defined in section
Standard toolkit on page 386.

Continues on next page

308 Product manual - IRB 910SC
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 4 Repair
4.6.2 Replacing the axis-2 drive unit
Continued

Required consumables
Consumable Article number Note
Cable ties -

Removing the axis-2 drive unit

Use these procedures to remove the axis-2 drive unit.

Preparations before removing the axis-2 drive unit

Action Note
1 Jog all axes to zero position.

xx1500002227

2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the main cable package from the upper arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.6.2 Replacing the axis-2 drive unit
Continued

Action Note
2 Remove the dome nuts and washers.

xx1500002182

3 Carefully open the user interface plate and

pull out the cable package.

CAUTION

The plate cannot be removed completely

until the connectors are disconnected, as
shown in the following step.

xx1500002183

4 Disconnect the connectors:

• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

Tip

Take photos of the connectors and cable xx1500002184

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002185

Removing the upper arm

Note

Two persons working together are required to perform this procedure.

Continues on next page
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 4 Repair
4.6.2 Replacing the axis-2 drive unit
Continued

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

The upper arm weights 13.2 kg. It may drop

by the force of gravity when it is released
from the lower arm. Make sure the weight
of the upper arm body is properly suppor-
ted.

3
Note

Two persons working together are required

to perform this step.
Person 1: Hold the upper arm.
Person 2: Remove the screws that fasten
the upper arm to the lower arm.

4 Remove the screws and washers.

WARNING

Keep the twelve screws in the outer circle

fitted. They hold the axis-2 motor flange on
the lower arm.

xx1500002256

xx1500002257

5 Remove the upper arm and lay it aside on

a workbench.

Removing the upper cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.6.2 Replacing the axis-2 drive unit
Continued

Action Note
2
WARNING

Risk of tipping. Make sure the robot is well

secured and that the upper arm is suppor-
ted during the removal work.

3 Remove the screws.

xx1500002220

4
WARNING

The cover may be damaged due to improp-

er shift. Keep the cover in position while
removing the screws.

5 Lift out the upper cover carefully.

xx1500002221

Removing the drive unit cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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 4 Repair
4.6.2 Replacing the axis-2 drive unit
Continued

Action Note
2 Cut the cable ties.
Be careful not to damage the cabling.

Tip

Take photos of the cable position before

removing them, to have as a reference
when refitting.

xx1500002226

Removing the cable harness plate

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the screws and washers.

3 Remove the cable harness plate.

xx1500002228

Removing the axis-2 drive unit

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

There is a risk of tipping during the remov-

al. Make sure the gravity center is well
supported.

Continues on next page

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4 Repair
4.6.2 Replacing the axis-2 drive unit
Continued

Action Note
3 Remove drive unit screws and washers.

WARNING

Pay attention to the screw positions and

keep the others fitted. The other screws
hold the gearbox together. Removing them
can damage the gearbox severely.

xx1500002496

4
Tip

If the drive unit is hard to be removed, in-

sert two M2 screws to the press out holes
and press out the drive unit.

xx1500002498

Refitting the axis-2 drive unit

Use these procedures to refit the axis-2 drive unit.

Refitting the axis-2 drive unit

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.
2 Refit the axis-2 drive unit into the upper Axis-2 drive unit: 3HAC056153-001
arm.

CAUTION

Do not mix axis-1 and axis-2 drive units.

Always check the mark or label on the drive
units before refitting.

Note

Make sure to refit the drive unit correctly

oriented, that is, the motor connectors
xx1500002496
should point to the end where the ball
screw spline unit is to be fitted. Screw: M4x25 (12 pcs)
Tightening torque: 4.5 Nm
3 Refit the screws and washers.
Washer: 4.3x9x1 (12 pcs)

Continues on next page

314 Product manual - IRB 910SC
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 4 Repair
4.6.2 Replacing the axis-2 drive unit
Continued

Refitting the cable harness plate

Action Note
1 Refit the cable harness plate.
2 Secure with screws and washers.

xx1500002228

Screw: M3x8 (4 pcs)

Tightening torque: 1.5 Nm
Washer: M3 (4 pcs)

Securing the drive unit cables

Action Note
1 Put the drive unit cables in place.

xx1500003063

A R2.ME3
B R2.MP2
C R2.MP3
D R2.MP4
E R2.ME2
F R2. ME4

2 Secure the cables with cable ties.

Do not tighten the ties too tight.

xx1500002226

Continues on next page

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4 Repair
4.6.2 Replacing the axis-2 drive unit
Continued

Refitting the upper cover

Action Note
1 Carefully put down the upper cover, avoid- Upper cover unit: 3HAC057615-001
ing any collision to the ball screw spline
unit and drive units.

xx1500002221

2
Tip

Some of the screws are accessed from

below. Make sure that the robot is properly
fastened and hang out the upper arm from
the workbench to access them.

3 Refit the cover.

xx1500002220

Screw: M4x16 (6 pcs)

Tightening torque: 2 Nm

Refitting the upper arm

Note

Two persons working together are required to perform this procedure.

Action Note
1
Note

Two persons working together are required

to perform this step.
Person 1: Hold the upper arm.
Person 2: Refit the screws that fasten the
upper arm to the lower arm.

Continues on next page

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 4 Repair
4.6.2 Replacing the axis-2 drive unit
Continued

Action Note
2 Make sure the lower arm is secured. Lower
the upper arm down onto the right place of
the lower arm.
3 Refit the upper arm screws and washers.

xx1500002256

Screw: M4x20 (16 pcs)

Tightening torque: 4.5 Nm
Washer: 4.3x9x1.3 (16 pcs)

Refitting the main cable to the upper arm

Action Note
1 Secure the main cable package with cable
ties if needed.
2 Reconnect the connectors.
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

xx1500002184

xx1500002185

Continues on next page

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4 Repair
4.6.2 Replacing the axis-2 drive unit
Continued

Action Note
3 Push the main cable package into place.

xx1500002207

4 Refit the user interface plate.

xx1500002182

Dome nut: M4 (6 pcs)

Tightening torque: 2 Nm
Washer, 6 pcs

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

318 Product manual - IRB 910SC

3HAC056430-001 Revision: M
© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.6.3 Replacing the axis-3 drive unit

4.6.3 Replacing the axis-3 drive unit

Location of the axis-3 drive unit

The axis-3 drive unit is located as shown in the figure.

xx1500002219

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Axis-3 drive unit 3HAC056111-001 Includes axis-3 gearbox, motor
and motor adapter.
Upper cover unit 3HAC057615-001 Includes upper cover and cover
flange.
Plain washer 3HAC056937-001 Replace if damaged.
Axis-3 drive unit housing 3HAC055184-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - The content is defined in the section
Standard toolkit on page 386.

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Equipment Article number Note

Sonic tensiometer - Used for measuring the timing belt
tension.
Dynamometer - Used for measuring the timing belt
tension.

Required consumables
Consumable Article number Note
Cable ties -

Removing the axis-3 drive unit

Use these procedures to remove the axis-3 drive unit.

Preparations before removing the axis-3 drive unit

Action Note
1 Jog axis 2 to access the cover screws.

xx1500002520

xx1500002782

Continues on next page

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 4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the main cable package from the upper arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the dome nuts and washers.

xx1500002182

3 Carefully open the user interface plate and

pull out the cable package.

CAUTION

The plate cannot be removed completely

until the connectors are disconnected, as
shown in the following step.

xx1500002183

Continues on next page

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4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Action Note
4 Disconnect the connectors:
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

Tip

Take photos of the connectors and cable xx1500002184

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002185

Removing the upper cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the robot is well

secured and that the upper arm is suppor-
ted during the removal work.

3 Remove the screws.

xx1500002220

Continues on next page

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 4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Action Note
4
WARNING

The cover may be damaged due to improp-

er shift. Keep the cover in position while
removing the screws.

5 Lift out the upper cover carefully.

xx1500002221

Removing the drive unit cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Cut the cable ties.

Be careful not to damage the cabling.

Tip

Take photos of the cable position before

removing them, to have as a reference
when refitting.

xx1500002226

Removing the axis-3 timing belt

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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© Copyright 2016-2021 ABB. All rights reserved.
4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Action Note
2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

3 Loosen the screws and move the axis-3

drive unit upwards to slacken the timing
belt.

xx1500002229

4 Remove the timing belt.

xx1500002230

Removing the axis-3 housing and axis-3 drive unit

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

Continues on next page

324 Product manual - IRB 910SC
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© Copyright 2016-2021 ABB. All rights reserved.
 4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Action Note
3 Remove the screws and washers.

xx1500002810

4 Lift out the axis-3 housing and drive unit.

xx1500002238

5 Cut the cable tie.

Be careful not to damage the cabling.

xx1500002815

Continues on next page

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4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Action Note
6 Remove the screws.

WARNING

Do not remove the other screws. They hold

the gearbox together. Removing them can
damage the gearbox severely.

xx1500002797

7 Lift out the axis-3 drive unit carefully.

xx1500002239

Continues on next page

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 4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Refitting the axis-3 drive unit

Use these procedures to refit the axis-3 drive unit.

Refitting the axis-3 housing and axis-3 drive unit

Action Note
1 Refit the drive unit with one cabling coming Axis-3 drive unit: 3HAC056111-001
out from the upside and the other coming Axis-3 drive unit housing: 3HAC055184-
out from the downside. 001

Note

Make sure to refit the drive unit correctly

oriented with the lugs of the drive unit
bracket as a reference.

2 Secure the upper cabling with a cable tie.

Do not tighten the tie too tight.

xx1500002815

3 Refit drive unit screws and washers just

enough to still be able to move the drive
unit.

xx1500002797

Screw: M4x20 (3 pcs)

Tightening torque: 4.5 Nm
Washer (3HAC056937-001, 3 pcs)

Note

Only use specified washers, never replace

them with other washers.

Continues on next page

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4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Action Note
4 Refit the housing with drive unit.

xx1500002798

Screw: M4x40 (4 pcs)

Tightening torque: 3.5 Nm
Washer: M4 (4 pcs)

Refitting the axis-3 timing belt

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.
2 Refit axis-3 timing belt. Ensure that the belt Axis-3 timing belt: 3HAC055209-001
runs correctly in the grooves.

xx1500002789

Continues on next page

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 4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Action Note
3 Fasten the screws little by little while using
a dynamometer to measure the belt tension
until a proper belt tension is achieved.

xx1500002229

Belt tension: F = 34 N (Recommended)

Belt tension range:
21.8 N to 24.9 N (for used timing belt, which
has been installed and used for more than
24 hours)
31.1 to 34.2 N (for new timing belt)

Securing the drive unit cables

Action Note
1 Put the drive unit cables in place.

xx1500003063

A R2.ME3
B R2.MP2
C R2.MP3
D R2.MP4
E R2.ME2
F R2. ME4

2 Secure the cables with cable ties.

Do not tighten the ties too tight.

xx1500002226

Continues on next page

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4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Refitting the upper cover

Action Note
1 Carefully put down the upper cover, avoid- Upper cover unit: 3HAC057615-001
ing any collision to the ball screw spline
unit and drive units.

xx1500002221

2
Tip

Some of the screws are accessed from

below. Make sure that the robot is properly
fastened and hang out the upper arm from
the workbench to access them.

3 Refit the cover.

xx1500002220

Screw: M4x16 (6 pcs)

Tightening torque: 2 Nm

Refitting the main cable to the upper arm

Action Note
1 Secure the main cable package with cable
ties if needed.

Continues on next page

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 4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Action Note
2 Reconnect the connectors.
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

xx1500002184

xx1500002185

3 Push the main cable package into place.

xx1500002207

4 Refit the user interface plate.

xx1500002182

Dome nut: M4 (6 pcs)

Tightening torque: 2 Nm
Washer, 6 pcs

Continues on next page

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4 Repair
4.6.3 Replacing the axis-3 drive unit
Continued

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

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 4 Repair
4.6.4 Replacing the axis-4 drive unit

4.6.4 Replacing the axis-4 drive unit

Location of the axis-4 drive unit

The axis-4 drive unit is located as shown in the figure.

xx1500002215

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRB 910SC via myABB Business Portal,
www.abb.com/myABB.

Spare part Article number Note

Axis-4 drive unit 3HAC056112-001 Includes axis-4 gearbox, motor
and motor adapter.
Upper cover unit 3HAC057615-001 Includes upper cover and cover
flange.
Plain washer 3HAC056937-001 Replace if damaged.

Required tools and equipment

Equipment Article number Note

Standard toolkit - The content is defined in the section
Standard toolkit on page 386.
Sonic tensiometer - Used for measuring the timing belt
tension.

Continues on next page

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4 Repair
4.6.4 Replacing the axis-4 drive unit
Continued

Equipment Article number Note

Dynamometer - Used for measuring the timing belt
tension.

Required consumables
Consumable Article number Note
Cable ties -

Removing the axis-4 drive unit

Use these procedures to remove the axis-4 drive unit.

Preparations before removing the axis-4 drive unit

Action Note
1 Jog axis 2 to access the cover screws.

xx1500002520

xx1500002782

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 4 Repair
4.6.4 Replacing the axis-4 drive unit
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

Removing the main cable package from the upper arm

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Remove the dome nuts and washers.

xx1500002182

3 Carefully open the user interface plate and

pull out the cable package.

CAUTION

The plate cannot be removed completely

until the connectors are disconnected, as
shown in the following step.

xx1500002183

Continues on next page

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4 Repair
4.6.4 Replacing the axis-4 drive unit
Continued

Action Note
4 Disconnect the connectors:
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

Tip

Take photos of the connectors and cable xx1500002184

position before disconnecting them, to have
as a reference when reconnecting.

xx1500002185

Removing the upper cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the robot is well

secured and that the upper arm is suppor-
ted during the removal work.

3 Remove the screws.

xx1500002220

Continues on next page

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 4 Repair
4.6.4 Replacing the axis-4 drive unit
Continued

Action Note
4
WARNING

The cover may be damaged due to improp-

er shift. Keep the cover in position while
removing the screws.

5 Lift out the upper cover carefully.

xx1500002221

Removing the drive unit cables

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2 Cut the cable ties.

Be careful not to damage the cabling.

Tip

Take photos of the cable position before

removing them, to have as a reference
when refitting.

xx1500002226

Removing the lower cover

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

Continues on next page

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4 Repair
4.6.4 Replacing the axis-4 drive unit
Continued

Action Note
2 Remove the screws.

xx1500002785

3 Remove the cover.

Tip

If only working with lower axis-4 timing belt,

no need to remove the stop block of ball
screw spline unit before removing the lower
cover.

xx1500002225

Removing the axis-4 drive unit and upper timing belt

Action Note
1
DANGER

Make sure that all supplies for electrical

power, hydraulic pressure, and air pressure
are turned off.

2
WARNING

Risk of tipping. Make sure the gravity cen-

ter is well supported.

3 Loosen the screws and move the axis-4

drive unit upwards to slacken the upper
axis-4 timing belt.

xx1500002233

Continues on next page

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 4 Repair
4.6.4 Replacing the axis-4 drive unit
Continued

Action Note
4 Remove the drive unit and timing belt.

xx1500002234

Refitting the axis-4 drive unit

Use these procedures to refit the axis-4 drive unit.

Refitting the axis-4 drive unit and upper timing belt

Action Note
1 Make sure that:
• all assembly surfaces are clean and
undamaged.
• the drive unit is clean and undam-
aged.
2 Place the timing belt. Axis-4 drive unit: 3HAC056112-001
Upper axis-4 timing belt: 3HAC055206-001

xx1500002801

Continues on next page

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4 Repair
4.6.4 Replacing the axis-4 drive unit
Continued

Action Note
3 Refit the drive unit and timing belt.

Note

Make sure to refit the drive unit with motor

connectors pointing against axis-3 drive
unit.

xx1500002802

4 Refit screws and washers just enough to

still be able to move the drive unit upwards.

xx1500002803

Screw: M4x16 (3 pcs)

Washer (3HAC056937-001, 3 pcs)

Note

Only use specified washers, never replace

them with other washers.

5 Fasten the screws little by little while using

a dynamometer to measure the belt tension
until a proper belt tension is achieved.

xx1500002233

Belt tension: F = 37 N (Recommended)

Belt tension range:
24.1 N to 27.6 N (for used timing belt, which
has been installed and used for more than
24 hours)
34.5 N to 37.9 N (for new timing belt)

Continues on next page

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 4 Repair
4.6.4 Replacing the axis-4 drive unit
Continued

Securing the drive unit cables

Action Note
1 Put the drive unit cables in place.

xx1500003063

A R2.ME3
B R2.MP2
C R2.MP3
D R2.MP4
E R2.ME2
F R2. ME4

2 Secure the cables with cable ties.

Do not tighten the ties too tight.

xx1500002226

Refitting the upper cover

Action Note
1 Carefully put down the upper cover, avoid- Upper cover unit: 3HAC057615-001
ing any collision to the ball screw spline
unit and drive units.

xx1500002221

Continues on next page

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4 Repair
4.6.4 Replacing the axis-4 drive unit
Continued

Action Note
2
Tip

Some of the screws are accessed from

below. Make sure that the robot is properly
fastened and hang out the upper arm from
the workbench to access them.

3 Refit the cover.

xx1500002220

Screw: M4x16 (6 pcs)

Tightening torque: 2 Nm

Refitting the lower cover

Action Note
1 Refit the cover. Lower cover: 3HAC060106-001

xx1500002225

2 Secure with screws.

xx1500002785

Screw: M4x8 (4 pcs)

Tightening torque: 2 Nm

Continues on next page

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 4 Repair
4.6.4 Replacing the axis-4 drive unit
Continued

Refitting the main cable to the upper arm

Action Note
1 Secure the main cable package with cable
ties if needed.
2 Reconnect the connectors.
• R2.MP2
• R2.MP3
• R2.MP4
• R2.ME2
• R2.ME3
• R2.ME4

xx1500002184

xx1500002185

3 Push the main cable package into place.

xx1500002207

Continues on next page

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4 Repair
4.6.4 Replacing the axis-4 drive unit
Continued

Action Note
4 Refit the user interface plate.

xx1500002182

Dome nut: M4 (6 pcs)

Tightening torque: 2 Nm
Washer, 6 pcs

Concluding procedure

Action Note
1 Recalibrate the robot. Calibration is detailed in section Calibration
on page 345.
2
DANGER

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section "First test
run may cause injury or damage" in Safety
manual for robot - Manipulator and IRC5
or OmniCore controller.

344 Product manual - IRB 910SC

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© Copyright 2016-2021 ABB. All rights reserved.
 5 Calibration
5.1.1 Introduction and calibration terminology

5 Calibration
5.1 Introduction to calibration

5.1.1 Introduction and calibration terminology

Calibration information
This chapter includes general information about the recommended calibration
methods and also the detailed procedures for updating the revolution counters,
checking the calibration position etc.

Calibration terminology

Term Definition
Calibration method A collective term for several methods that might be
available for calibrating the ABB robot. Each method
contains calibration routines.
Synchronization position Known position of the complete robot where the
angle of each axis can be checked against visual
synchronization marks.
Calibration position Known position of the complete robot that is used
for calibration of the robot.
Standard calibration A generic term for all calibration methods that aim
to move the robot to calibration position.
Fine calibration A calibration routine that generates a new zero posi-
tion of the robot.
Reference calibration A calibration routine that in the first step generates
a reference to current zero position of the robot. The
same calibration routine can later on be used to re-
calibrate the robot back to the same position as when
the reference was stored.
This routine is more flexible compared to fine calib-
ration and is used when tools and process equipment
are installed.
Requires that a reference is created before being
used for recalibrating the robot.
Requires that the robot is dressed with the same
tools and process equipment during calibration as
during creation of the reference values.
Update revolution counter A calibration routine to make a rough calibration of
each manipulator axis.
Synchronization mark Visual marks on the robot axes. When marks are
aligned, the robot is in synchronization position.

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5 Calibration
5.1.2 Calibration methods

5.1.2 Calibration methods

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

Types of calibration

Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration Manual calibration
position.
Standard calibration data is found on the SMB
(serial measurement board) or EIB 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.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at synchronization posi-
al) tion, the Absolute accuracy calibration also
compensates for:
• Mechanical tolerances in the robot
structure
• Deflection due to load
Absolute accuracy calibration focuses on pos-
itioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with Absolute accuracy has
a sticker next to the identification plate of the
robot.
To regain 100% Absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy after repair or maintenance that
affects the mechanical structure.

xx0400001197

Continues on next page

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 5 Calibration
5.1.2 Calibration methods
Continued

Brief description of calibration methods

Manual calibration method
With the manual calibration method, the robot's axes are positioned in specific
calibration positions using calibration tools. Under this condition, the position of
the axis to be calibrated is pre-determined. The axes must be calibrated one at a
time.

CalibWare - Absolute Accuracy calibration

The CalibWare tool guides through the calibration process and calculates new
compensation parameters. This is further detailed in the Application
manual - CalibWare Field.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after replacements that do not include taking apart the robot
structure, standard calibration is sufficient.

References
Article numbers for the calibration tools are listed in the section Special tools on
page 387.

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5 Calibration
5.1.3 When to calibrate

5.1.3 When to calibrate

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

The resolver values are changed

If resolver values are changed, the robot must be re-calibrated using the calibration
methods supplied by ABB. Calibrate the robot carefully with standard calibration,
according to information in this manual.
If the robot has absolute accuracy calibration, it is also recommended, but not
always necessary to calibrate for new absolute accuracy.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.

The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 351. This will occur when:
• The battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are
connected at the first installation.

The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot
is changed, it needs to be re-calibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.

348 Product manual - IRB 910SC

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© Copyright 2016-2021 ABB. All rights reserved.
 5 Calibration
5.2.1 Synchronization marks and synchronization position for axes

5.2 Synchronization marks and axis movement directions

5.2.1 Synchronization marks and synchronization position for axes

Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
     
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5 Calibration
5.2.2 Calibration movement directions for all axes

5.2.2 Calibration movement directions for all axes

Overview
When calibrating, the axis must consistently be run towards the calibration position
in the same direction in order to avoid position errors caused by backlash in gears
and so on. Positive directions are shown in the graphic below.
Calibration service routines will handle the calibration movements automatically
and these might be different from the positive directions shown below.

Manual movement directions

xx1500002631

Posi- Description Posi- Description

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

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 5 Calibration
5.3 Updating revolution counters

5.3 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.

Coupled axes
When updating the revolution counters for a coupled axis, also the axis it is coupled
to needs to be at its synchronization position for the update to be correct; i.e. axis
4 needs to be in synchronization position when updating axis 5 and 6.
With reversed coupled joints, the relationship is the opposite, i.e. axis 4 needs to
be in synchronization position to update axis 3.
Coupled axes

IRB 910 SC
IRB 1600ID

IRB 1660ID

IRB 2600ID

IRB 4450S
IRB 1410

IRB 1520

IRB 1600

IRB 2400

IRB 2600

IRB 4400

IRB 4600
IRB 140

Axis 4, 5, 6 x x x x x x x
Axis 5, 6 x x x x x
Axis 4, 3 x

Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.
Action Note
1 Select axis-by-axis motion mode.
2 Jog the manipulator to align the synchron- See Synchronization marks and synchron-
ization marks. ization position for axes on page 349.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 352.

Continues on next page

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5 Calibration
5.3 Updating revolution counters
Continued

Correct calibration position of axes 3 and 4

When jogging the manipulator to synchronization position, it is extremely important
to make sure that axes 3 and 4 are positioned correctly. Axis 4 can be calibrated
at the wrong turn, resulting in an incorrect axis 3 calibration position and manipulator
calibration.
Make sure the notch on the stop block points to the center of fixing calibration
block, and the distance between lower surfaces of shaft and fixing calibration block
is 33 mm.

xx1500002907

At delivery the manipulator is in the correct position. Do NOT shift axis 3 or rotate
axis 4 at power up before the revolution counters are updated.
If axis 4 is rotated one or more turns from its calibration position before updating
the revolution counter, the correct calibration position will be lost due to non-integer
gear ratio. This will further affect the calibration position of axis 3.

Step 2 - Updating the revolution counter with the FlexPendant

Note

Revolution counters of axes 3 and 4 must be updated together.

Continues on next page

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 5 Calibration
5.3 Updating revolution counters
Continued

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

xx1500000942

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

xx1500000943

Continues on next page

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5 Calibration
5.3 Updating revolution counters
Continued

Action
3 A screen is displayed, tap Rev. Counters.

en0400000771

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 373.

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 5 Calibration
5.4.1 Calibration position

5.4 Calibrating the robot

5.4.1 Calibration position

Calibration position
The position of the axis to be calibrated is illustrated in each calibration section
respectively.
The table below specifies the exact axis positions in degrees.
Axis IRB 910SC-3/0.45 IRB 910SC-3/0.55 IRB 910SC-3/0.65
1 -6.9199168° -6.9199168° -6.9199168°
2 -7.12701982° -7.12701982° -7.12701982°
3 0 mm 0 mm 0 mm
4 0° 0° 0°

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5 Calibration
5.4.2 Calibrating axis 1

5.4.2 Calibrating axis 1

Calibration position of axis 1

The figure shows axis 1 in calibration position, with calibration tools fitted.

xx1500002512

Required equipment
Calibration of axis 1 is done by moving the lower arm so that the moving calibration
pin and calibration block touches each other gently.
The calibration block is already fitted to the robot.

Continues on next page

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 5 Calibration
5.4.2 Calibrating axis 1
Continued

See figures below for reference, and follow the step-by-step procedure that follows.

xx1500002516

A Moving calibration pin

B Calibration block

Required consumables
Equipment Art. no. Note
Cleaning agent - Isopropanol

Calibrating axis 1
Moving the robot to calibration position
Action Note
1 Jog axis 1 to a suitable position where the calibra-
tion pin can be fitted in to the press fit bushing.

xx1500002808

Continues on next page

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5 Calibration
5.4.2 Calibrating axis 1
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

3 Fit the calibration pin to the press fit bushing.

xx1500002509

4 Turn on the electric power to the robot.

5
DANGER

When releasing the holding brakes, the robot axes

may move very quickly and sometimes in unex-
pected ways!
Make sure the payload is disassembled or tooling
is properly supported; otherwise, fast downward
movements of axis 3 may cause severe hits.

6 Release the brakes and manually rotate axis 1 See Manually releasing the brakes
until the calibration pin touches the calibration on page 61.
block gently. There should be no pressing force
between them.

xx1500002508

7
CAUTION

Pay attention to robot pose in order to avoid arm

collision.

8 Release the brake release button to activate the

brakes.

Continues on next page

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 5 Calibration
5.4.2 Calibrating axis 1
Continued

Performing the fine calibration procedure

Action Note
1
WARNING

Do not fine calibrate the robot without special

equipment used for axis calibration! It would
cause an unsatisfied accuracy in the robot
movement.

2 Choose fine calibration from Calib menu.

On the ABB menu, tap Calibration.
All mechanical units connected to the system are
shown along with their calibration status.
3 Tap to select the mechanical unit and then tap Calib. Parameters.

en0400001127

4 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 dialog box is displayed, warning that updating
the revolution counters may change programmed
robot positions:
• Tap Yes to proceed.
• Tap No to cancel.
5 Select the check-box for the current axis/axes to
be calibrated.

Continues on next page

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5 Calibration
5.4.2 Calibrating axis 1
Continued

Action Note
6 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.

Checking and finalizing the calibration

Action Note
1
DANGER

Always remember to remove the calibration tools

from the robot before jogging axes to zero position
during calibration.

2 Release the brakes and manually rotate the axis

to apart the calibration pins from each other. This
is done to avoid damage on the pins if incorrect
operation should occur during next step of jog-
ging.
3 Jog axis 1 to zero degree using the FlexPendant.
4 Check that the synchronization marks on axis 1
are aligned with each other.
Are they aligned within the tolerances?
• If yes, the calibration is verified OK.
• If no, redo the fine calibration procedure.

xx1500002514

After calibration
Action Note
1 Write down the new system parameters on a new
label and stick on top of the calibration label on
the robot.

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 5 Calibration
5.4.3 Calibrating axis 2

5.4.3 Calibrating axis 2

Calibration position of axis 2

The figure shows axis 2 in calibration position.

xx1500002513

Required equipment
Calibration of axis 2 is done by moving the lower arm so that the moving calibration
pin and calibration block touches each other gently.
The calibration block is already fitted to the robot.

Continues on next page

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5 Calibration
5.4.3 Calibrating axis 2
Continued

See figures below for reference, and follow the step-by-step procedure that follows.

xx1500002516

A Moving calibration pin

B Calibration block

Required consumables
Equipment Art. no. Note
Cleaning agent - Isopropanol

Calibrating axis 2
Moving the robot to calibration position
Action Note
1 Jog axis 2 to a suitable position where the calibra-
tion pin can be fitted to the press fit bushing.

xx1500002809

Continues on next page

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 5 Calibration
5.4.3 Calibrating axis 2
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

3 Fit the calibration pin to the press fit bushing.

xx1500002511

4 Turn on the electric power to the robot.

5
DANGER

When releasing the holding brakes, the robot axes

may move very quickly and sometimes in unex-
pected ways!
Make sure the payload is disassembled or tooling
is properly supported; otherwise, fast downward
movements of axis 3 may cause severe hits.

6 Release the brakes and manually rotate axis 2 See Manually releasing the brakes
until the calibration pin touches the calibration on page 61.
block gently. There should be no pressing force
between them.

xx1500002510

7
CAUTION

Pay attention to robot pose in order to avoid arm

collision.

8 Release the brake release button to activate the

brakes.

Continues on next page

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5 Calibration
5.4.3 Calibrating axis 2
Continued

Performing the fine calibration procedure

Action Note
1
WARNING

Do not fine calibrate the robot without special

equipment used for axis calibration! It would
cause an unsatisfied accuracy in the robot
movement.

2 Choose fine calibration from Calib menu.

On the ABB menu, tap Calibration.
All mechanical units connected to the system are
shown along with their calibration status.
3 Tap to select the mechanical unit and then tap Calib. Parameters.

en0400001127

4 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 dialog box is displayed, warning that updating
the revolution counters may change programmed
robot positions:
• Tap Yes to proceed.
• Tap No to cancel.
5 Select the check-box for the current axis/axes to
be calibrated.

Continues on next page

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 5 Calibration
5.4.3 Calibrating axis 2
Continued

Action Note
6 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.

Checking and finalizing the calibration

Action Note
1
DANGER

Always remember to remove the calibration tools

from the robot before jogging axes to zero position
during calibration.

2 Release the brakes and manually rotate the axis

to apart the calibration pins from each other. This
is done to avoid damage on the pins if incorrect
operation should occur during next step of jog-
ging.
3 Jog axis 2 to zero degree using the FlexPendant.
4 Check that the synchronization marks on axis 2
are aligned with eachother.
Are they aligned within the tolerances?
• If yes, the calibration is verified OK.
• If no, redo the fine calibration procedure.

xx1500002515

After calibration
Action Note
1 Write down the new system parameters on a new
label and stick on top of the calibration label on
the robot.

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5 Calibration
5.4.4 Calibrating axis 3 and axis 4

5.4.4 Calibrating axis 3 and axis 4

Calibration position of axis 3 and axis 4

The figure shows axis 3 and axis 4 in calibration position. The axes 3 and 4 are
calibrated together.

xx1500002499

Required equipment
Axes 3 and 4 are calibrated together. The calibration is done by moving the ball
screw spline unit so that the calibration pin on the moving calibration block and
the fixing calibration block touch each other gently.
The fixing calibration block is already fitted to the robot.

Continues on next page

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 5 Calibration
5.4.4 Calibrating axis 3 and axis 4
Continued

See figures below for reference, and follow the step-by-step procedure that follows
the figures.
Moving calibration block (including calibra- Fixing calibration block (including parallel
tion pin, knob and adjusting screw) pins and attachment screws)

xx1500002500

A Knob
B Moving calibration block
C Calibration pin
D Screw xx1500002501

A Parallel pin
B Fixing block
C Screw

Required consumables
Equipment Art. no. Note
Cleaning agent - Isopropanol

Calibrating axis 3 and axis 4

Moving the robot to calibration position
Action Note
1 Jog axis 3 and axis 4 to find a suitable position
where axis-3/4 calibration tools can be fitted.

xx1500002502

Continues on next page

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5 Calibration
5.4.4 Calibrating axis 3 and axis 4
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

3 Fit the moving calibration block with its flat part

aligned with the shaft flat mark.

xx1500002503

A Shaft flat mark

B Block flat part
4 When the lower surfaces of the shaft and block
are at the same level, tighten the screw slowly to
a degree just enough to ensure the block not drop.

xx1500002504

5 Turn the knob gently until its sphere head is

properly inserted into the conical hole.

xx1500002505

6 Tighten the screw to lock the block on the shaft.

7 Turn on the electric power to the robot.

Continues on next page

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 5 Calibration
5.4.4 Calibrating axis 3 and axis 4
Continued

Action Note
8
DANGER

When releasing the holding brakes, the robot axes

may move very quickly and sometimes in unex-
pected ways!
Make sure the payload is disassembled or tooling
is properly supported; otherwise, fast downward
movements of axis 3 may cause severe hits.

9 Release the brakes and manually move the ball How to release the brakes is de-
screw spline up and down until: tailed in Manually releasing the
• the calibration pin on the moving calibration brakes on page 61.
block locates in the groove of the fixing
calibration block and;
• the contact surfaces of the calibration pin
and fixing calibration block touches each
other gently; there should be no pressing
force between the surfaces.
When doing this, pay attention to robot pose in
order to avoid arm collision.
When the axes are in position, release the brake
release button to activate the brakes again. xx1500002506

Performing the fine calibration procedure

Action Note
1
WARNING

Do not fine calibrate the robot without special

equipment used for axis calibration! It would
cause an unsatisfied accuracy in the robot
movement.

2 Choose fine calibration from Calib menu.

On the ABB menu, tap Calibration.
All mechanical units connected to the system are
shown along with their calibration status.

Continues on next page

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5 Calibration
5.4.4 Calibrating axis 3 and axis 4
Continued

Action Note
3 Tap to select the mechanical unit and then tap Calib. Parameters.

en0400001127

4 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 dialog box is displayed, warning that updating
the revolution counters may change programmed
robot positions:
• Tap Yes to proceed.
• Tap No to cancel.
5 Select the check-box for the current axis/axes to
be calibrated.
6 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.

Continues on next page

370 Product manual - IRB 910SC
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 5 Calibration
5.4.4 Calibrating axis 3 and axis 4
Continued

Checking and finalizing the calibration

Action Note
1
DANGER

Always remember to remove the calibration tools

from the robot before jogging axes to zero position
during calibration.

2 Release the brakes and manually rotate the axis

to apart the calibration pins from each other. This
is done to avoid damage on the pins if incorrect
operation should occur during next step of jog-
ging.
3 Jog axes 3 and 4 to zero degree using the Flex-
Pendant.
4 Check that the synchronization marks on axes 3
and 4 are aligned with each other.
Are they aligned within the tolerances?
• If yes, the calibration is verified OK.
• If no, redo the fine calibration procedure.

xx1500002507

After calibration
Action Note
1 Write down the new system parameters on a new
label and stick on top of the calibration label on
the robot.

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5 Calibration
5.5 Verifying the calibration

5.5 Verifying the calibration

Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.

Verifying the calibration

Use this procedure to verify the calibration result.
Action Note
1 Run the calibration home position program twice. See Checking the synchron-
Do not change the position of the robot axes after running ization position on page 373.
the program!
2 Adjust the synchronization marks when the calibration is This is detailed in section
done, if necessary. Synchronization marks and
synchronization position for
axes on page 349.
3 Write down the values on a new label and stick it on top
of the calibration label.
The label is located on the base.
4 Remove any calibration equipment from the robot.

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 5 Calibration
5.6 Checking the synchronization position

5.6 Checking the synchronization position

Introduction
Check the synchronization position of the robot before beginning any programming
of the robot system. This may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the FlexPendant.

Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 On ABB menu tap Program editor.
2 Create a new program.
3 Use MoveAbsJ in the Motion&Proc menu.
4 Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0

5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 349 and Updating revolution
counters on page 351.

Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 On the ABB menu, tap Jogging.
2 Tap Motion mode to select group of axes
to jog.
3 Tap to select the axis to jog, axis 1, 2, or
3.
4 Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
5 Check that the synchronization marks for See Synchronization marks and synchron-
the axes align correctly. If they do not, up- ization position for axes on page 349 and
date the revolution counters. Updating revolution counters on page 351.

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This page is intentionally left blank
 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 Base, upper arm, lower arm, axis-3 housing, etc
Batteries, Lithium Battery pack
Neodymium Drive units
Oil, grease Drive units, ball screw spline unit
Plastic/rubber Upper arm cover, mechanical stop rubbers
Steel Drive units, ball screw spline unit, etc

Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.
Also note that:
• Spills can form a film on water surfaces causing damage to organisms.
Oxygen transfer could also be impaired.
• Spillage can penetrate the soil causing ground water contamination.

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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 as referred to from ISO 10218-1

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

Deviation for delay circuit

Some variants of IRB 910SC has an inherent delay circuit to enhance the lifetime
of speed reducers. This only applies to variants IRB 910SC-3/0.45, IRB
910SC-3/0.55, and IRB 910SC-3/0.65.
This circuit allows an extended time period for soft stop by enabling a delay of
about 0.5 s before motor brakes are engaged, e.g. when the three-position enabling
device is released or compressed, or the emergency stop is pressed. During this
period, the robot axes 1 and 2 will continue their movement until they are stopped
by the motor or eventually by brakes. Make sure the robot safeguarded area is
free from obstacles, even during manual operations. Note that this delay does not
apply to axes 3 and 4.
For more details regarding stopping time and distance metric, see Product
specification - Robot stopping distances according to ISO 10218-1.

Continues on next page

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 7 Reference information
7.2 Applicable standards
Continued

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

ISO 13732-1:2006 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 Specification of screws

7.4 Specification of screws

Screws, nuts and washers not handled as spare parts

The screws, nuts and washers listed have no special treatment and can be bought
locally if lost or damaged.

Screw/Nut/Washer Dimension, class and treatment

Hex socket head cap screw M5x16 12.9 Steel Black Oxide
Hex socket head cap screw M5x25 12.9 Steel Black Oxide
Hex socket head cap screw M6x30 12.9 Steel Black Oxide
Hex socket head cap screw M3x8 12.9 Steel Black Oxide
Hex socket head cap screw M3x20 12.9 Steel Black Oxide
Hex socket head cap screw M4x16 12.9 Steel Black Oxide
Hex socket head cap screw M4x25 12.9 Steel Black Oxide
Hex socket head cap screw M4x20 12.9 Steel Black Oxide
Hex socket head cap screw M5x12 12.9 Steel Black Oxide
Hex socket head cap screw M3x12 12.9 Steel Black Oxide
Hex socket head cap screw M4x12 12.9 Steel Black Oxide
Hex socket head cap screw M2.5x6 12.9 Steel Black Oxide
Hex socket head cap screw M4x30 12.9 Steel Black Oxide
Hex socket head cap screw M4x10 12.9 Steel Black Oxide
Hex socket head cap screw M6x16 8.8 Steel Zinc electroplated and chromated,
bluish
Torx pan head screw M3x4 8.8 Steel Zinc eletroplated and chromated, bluish
Torx pan head screw M3x6 8.8 Steel Zinc eletroplated and chromated, bluish
Hex socket counters. flat head M4x8 8.8 Steel Zinc electroplated and chromated,
screw bluish
Hex socket pan head thread rolling M3x6 8.8 Stainless steel Zinc electroplated and chro-
screw mated, bluish
Hexagon domed cap nut M4 DIN1587 Stainless steel A2
Hexagon nut M4 8 Steel Zinc electroplated and chromated, bluish
Plain washer 4.3x9x0.8 200HV Steel Zinc electroplated and chro-
mated, bluish
Plain washer 6.4x12x1.6 200HV Steel Zinc electroplated and chro-
mated, bluish
Plain washer 6.4x17x3 200HV Steel Zinc electroplated and chro-
mated, bluish
Conical spring washer 3.2x7x0.6 420-510HV Spring steel acc.to DIN267 Teil26
Zinc plated mechanically and chromated, bluish
Conical spring washer 4.3x9x1 420-510HV Spring steel acc.to DIN267 Teil26
Zinc plated mechanically and chromated, bluish
Conical spring washer 5.3x11x1.2 420-510HV Spring steel acc.to DIN267
Teil26 Zinc plated mechanically and chromated, bluish

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7 Reference information
7.5 Screw joints

7.5 Screw joints

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

UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints.
It features special surface treatment (Gleitmo as described below) and is extremely
resistant to fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other
type of replacement screw is allowed. Using other types of screws will void any
warranty and may potentially cause serious damage or injury.

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the
screw joint. 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.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the
repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.
Lubricant Article number
Molycote 1000 (molybdenum disulphide grease) 3HAC042472-001

Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.

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7.5 Screw joints
Continued

• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!

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

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.

Note

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

overrides the standard torque.

Oil-lubricated screws with allen head screws

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

Note

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

overrides the standard torque.

Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-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

Continues on next page

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7 Reference information
7.5 Screw joints
Continued

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
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
1/2 40 30 50
3/4 70 55 90

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 7 Reference information
7.6 Weight specifications

7.6 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
7.7 Standard toolkit

7.7 Standard toolkit

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

Contents, standard toolkit

Qty Tool Rem.

1 Socket head cap 2-17 mm
1 Torque wrench 0.3-45 Nm
1 Torque wrench 45 Nm For securing robot to
foundation.
1 Ratchet head for torque wrench 1/2
1 Hex socket head cap no. 2.5 socket 1/2" bit L=110 mm
1 Small screwdriver
1 T-handle with ball head
1 Small cutting plier
1 Plastic mallet

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 7 Reference information
7.8 Special tools

7.8 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 386, and of special tools, listed directly in the instructions
and also gathered in this section.

Special tools

Note

If the replacing procedure is not listed in the table below, only standard tools are
needed for the procedure.

Continues on next page

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7 Reference information
7.8 Special tools

Cable harness spare parts

Lower arm spare parts

Upper arm spare parts

Ball screw spline unit

Axis-4 timing belts

Axis-3 timing belt
Base spare parts

Axis-1 motor

Axis-2 motor

Axis-3 motor

Axis-4 motor
Tools and equipment with spare part number:
(These tools can be ordered from ABB)

Lifting accessories

Lifting accessory, robot

- Includes lifting accessories and
screws.

xx1500002471

Lifting chain, capacity > 50 kg.

-
Hook

Calibration toolkit

3HAC057036-001 Moving calibration pin 1 1 1 1 1 1

xx1500002518

Moving calibration block, axis3

and axis 4
3HAC057137-001 1 1 1 1 1
Includes calibration pin, knob and
adjusting screw.

xx1500002682

Other tools
- 24 VDC power supply 1
- Sonic tensiometer 1 1 1 1 1 1
- Dynamometer 1 1 1 1 1 1

Continues on next page

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 7 Reference information
7.9 Lifting accessories and lifting instructions

7.9 Lifting accessories and lifting instructions

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

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 8 Spare parts
8.1 Spare part lists and illustrations

8 Spare parts
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
 9 Circuit diagrams
9.1 Circuit diagrams

9 Circuit diagrams
9.1 Circuit diagrams

Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.abb.com/myABB.
See the article numbers in the tables below.

Controllers

Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Compact 3HAC049406-003
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 67, design 14 3HAC024120-005
Circuit diagram - Spot welding cabinet 3HAC057185-001

Robots

Product Article numbers for circuit diagrams

Circuit diagram - IRB 120 3HAC031408-003
Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 260 3HAC025611-001
Circuit diagram - IRB 360 3HAC028647-009
Circuit diagram - IRB 460 3HAC036446-005
Circuit diagram - IRB 660 3HAC025691-001
Circuit diagram - IRB 760 3HAC025691-001
Circuit diagram - IRB 1200 3HAC046307-003
Circuit diagram - IRB 1410 3HAC2800-3
Circuit diagram - IRB 1600/1660 3HAC021351-003
Circuit diagram - IRB 1520 3HAC039498-007
Circuit diagram - IRB 2400 3HAC6670-3
Circuit diagram - IRB 2600 3HAC029570-007
Circuit diagram - IRB 4400/4450S 3HAC9821-1
Circuit diagram - IRB 4600 3HAC029038-003
Circuit diagram - IRB 6620 3HAC025090-001
Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6640 3HAC025744-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001

Continues on next page

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9 Circuit diagrams
9.1 Circuit diagrams
Continued

Product Article numbers for circuit diagrams

Circuit diagram - IRB 6660 3HAC025744-001
3HAC029940-001
Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005
Circuit diagram - IRB 7600 3HAC13347-1
3HAC025744-001
Circuit diagram - IRB 14000 3HAC050778-003
Circuit diagram - IRB 910SC 3HAC056159-002

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 Index

Index cleaning, 114

climbing on robot, 32
Cold environments, 75
A connecting the robot and controller, cabling, 71
Absolute Accuracy, calibration, 347
allergenic material, 28 D
aluminum dimensions
disposal, 376 robot, 66
ambient humidity direction of axes, 350
operation, 43
storage, 42 E
ambient temperature EIB mounting plate
operation, 43 replacing, 164
storage, 42 EIB unit
assembly instructions, 39 replacing, 146
assessment of hazards and risks, 28 environmental information, 376
axis-4 drive unit equipment, robot, 66
replacing, 333 ESD
axis-3 drive unit damage elimination, 52
replacing, 319 sensitive equipment, 52
axis-3 timing belt extra equipment, 66
replacing, 246
axis-2 drive unit F
replacing, 308 fire extinguishing, 29
axis-2 mechanical stop fitting, equipment, 66
replacing, 271 FlexPendant
axis-1 drive unit jogging to calibration position, 373
replacing, 299 MoveAbsJ instruction, 373
axis-1 mechanical stop updating revolution counters, 352
replacing, 296 floor cables
replacing, 183
B foundation
ball screw spline unit requirements, 42
lubrication, 111
replacing, 229 G
base grease, 32
replacing, 285 disposal, 376
batteries
disposal, 376 H
battery pack hanging
replacing, 100 installed hanging, 28
brake release harness hazard levels, 19
replacing, 191 hazardous material, 376
brakes height
testing function, 36 installed at a height, 28
hot surfaces, 32
C HRA, 28
cabinet lock, 29 humidity
cabling, robot, 71 operation, 43
cabling between robot and controller, 71 storage, 42
calibrating
roughly, 351 I
calibration installation
Absolute Accuracy type, 346 equipment, 66
rough, 351 instructions for assembly, 39
standard type, 346 integrator responsibility, 28
verification, 372 intervals for maintenance, 80
when to calibrate, 348
calibration, Absolute Accuracy, 347 L
calibration manuals, 347 labels
calibration marks, 349 robot, 21
calibration position lifting accessory, 385
jogging to, 373 limitation of liability, 17
scales, 349 Lithium
calibration scales, 349 disposal, 376
CalibWare, 346 loads on foundation, 41
carbon dioxide extinguisher, 29 lock and tag, 29

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Index

lower arm report replacements, 117

replacing, 276 requirements on foundation, 42
lubricants, 32 responsibility and validity, 17
lubrication revolution counters
ball screw spline unit, 111 storing on FlexPendant, 352
updating, 351
M risk of burns, 32
main cable package risk of tipping, 50
replacing, 122 robot
maintenance intervals, 80 dimensions, 66
maintenance schedule, 80 equipment, fitting, 66
mounting, equipment, 66 labels, 21
MoveAbsJ instruction, 373 protection class, 43
protection types, 43
N symbols, 21
national regulations, 28 rubber
negative directions, axes, 350 disposal, 376
neodymium
disposal, 376 S
safety
O brake testing, 36
oil, 32 ESD, 52
disposal, 376 fire extinguishing, 29
operating conditions, 43 release robot axes, 35
original spare parts, 17 signals, 19
signals in manual, 19
P symbols, 19
PCB board symbols on robot, 21
replacing, 156 safety devices, 29
pedestal safety hazard
installed on pedestal, 28 hydraulic system, 30
personnel pneumatic system, 30
requirements, 18 safety signals
plastic in manual, 19
disposal, 376 safety standards, 378
positive directions, axes, 350 scales on robot, 349
PPE, 18 schedule of maintenance, 80
product standards, 378 screw joints, 382
protection classes, 43 securing, robot, 63
protection type, 43 signals
protective equipment, 18 safety, 19
protective wear, 18 speed
R adjusting, 75
regional regulations, 28 stability, 50
release brakes, 35 standards, 378
replacements, report, 117 ANSI, 379
replacing CAN, 379
axis-4 drive unit, 333 EN IEC, 378
axis-3 drive unit, 319 EN ISO, 378
axis-3 timing belt, 246 start of robot in cold environments, 75
axis-2 drive unit, 308 steel
axis-2 mechanical stop, 271 disposal, 376
axis-1 drive unit, 299 storage conditions, 42
axis-1 mechanical stop, 296 symbols
ball screw spline unit, 229 safety, 19
base, 285 synchronization position, 351
battery pack, 100 sync marks, 349
brake release harness, 191 system integrator requirements, 28
EIB mounting plate, 164
T
EIB unit, 146 temperatures
floor cables, 183 operation, 43
lower arm, 276 storage, 42
main cable package, 122 testing
PCB board, 156 brakes, 36
timing belts, 256 timing belts
upper arm, 196 replacing, 256

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 Index

torques on foundation, 41 velocity

troubleshooting adjusting, 75
safety, 37 verifying calibration, 372

U W
updating revolution counters, 351 weight, 41
upper arm robot, 58, 64
replacing, 196
users Z
requirements, 18 zero position
checking, 373
V
validity and responsibility, 17

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© Copyright 2016-2021 ABB. All rights reserved.
ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400

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

ABB Engineering (Shanghai) Ltd.

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

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

abb.com/robotics
3HAC056430-001, Rev M, en

© Copyright 2016-2021 ABB. All rights reserved.

Specifications subject to change without notice.