Page 1 ROBOTICS Product manual CRB 15000...
Page 2 Trace back information: Workspace 22A version a16 Checked in 2022-03-11 Skribenta version 5.4.005...
Page 4 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.
Page 5: Table Of Contents
Information about software for the CRB 15000 ..........3.6.2 Lead-through ..................3.6.3 The SafeMove configurator app on FlexPendant ........... 3.6.4 Guidelines for transient and quasi-static contact, CRB 15000 ......Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 6 Replacing the axis-1 joint unit ..............5.6.2 Replacing the axis-2 joint unit ..............5.6.3 Replacing the axis-3 joint unit ..............5.6.4 Replacing the axis-4 joint unit ..............Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 7 Scrapping of robot ..................... Reference information Introduction ...................... Applicable standards ..................Unit conversion ....................Screw joints ....................Weight specifications ..................Standard toolkit ....................Special tools ....................Index Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
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Page 9: Overview Of This Manual
The robot described in this manual has the following protection types: • Standard Product manual scope The manual covers all variants and designs of the CRB 15000. Some variants and designs may have been removed from the business offer and are no longer available for purchase. Usage This manual should be used during: •...
Page 10 3HAC066559-001 Application manual - Force Control Standard for GoFa 3HAC083267-001 Technical reference manual - Event logs for RobotWare 7 3HAC066553-001 All documents can be found via myABB Business Portal, www.abb.com/myABB. Revisions Revision Description First edition. Published in release 21B. The following updates are made in this revision: •...
Page 11 • Information about online user guide added in section The Safe- Move configurator app on FlexPendant on page • Added more information for laser scanners. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 12: Product Documentation
Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
Page 13 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. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 14: How To Read The Product Manual
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. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 15: Safety
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.
Page 16: Requirements On Personnel
Use personal protective equipment, as stated in the instructions. Risk of entanglement Loose clothing should not be worn and long hair should be tied up to reduce the risk for entanglement. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 17: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 18 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 19: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 20 Brake release Using the brake release tool will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 21 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 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 22 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Lifting bolt xx0900000821 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 23 No mechanical stop xx1000001144 Stored energy Warns that this part contains stored energy. Used in combination with Do not disassemble symbol. xx0900000825 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 24 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 Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 25: Robot Stopping Functions
• Product manual - OmniCore C30 Reasons for selection of stops in CRB 15000 For nearly all safety functions in CRB 15000, a category 1 stop is defined. Exceptions are only allowed: • When there is a technical fault in the system, or •...
Page 26: Safety During Installation And Commissioning
Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 27 Specific information for GoFa robots The CRB 15000 collaborative robot is designed to be able to work safely alongside humans and even share tasks with them. It is vital for the user of the robot to operate it in a safe way, setting up the necessary safety configurations, and ensure that appropriate risk reduction measures are implemented.
Page 28: Safety During Operation
Unexpected movement of robot arm WARNING Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 29: Safety During Maintenance And Repair
Follow the instructions in section Maintenance on page 131. Related information See also the safety information related to installation and operation. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 30: Emergency Release Of The Robot Axes
In an emergency situation, the brakes on a robot axis can be released manually by using a brake release tool. How to release the brakes is described in the section: • Manually releasing the brakes on page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 31: Brake Testing
For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 32: Safety During Troubleshooting
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.
Page 33: Safety During Decommissioning
1 Safety 1.8 Safety during decommissioning 1.8 Safety during decommissioning General See section Decommissioning on page 739. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
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Page 35: Manipulator Description
2.1 About CRB 15000 Introduction The CRB 15000 robot is a lightweight, flexible, agile 6-axis articulated robot, with a payload of 5 kg, designed specifically for manufacturing industries that use flexible robot-based automation. The robot has an open structure that is especially adapted for flexible use, and can communicate extensively with external systems.
Page 36: Technical Data
Force in any direction in the XY plane Force in the Z plane Bending torque in any direction in the XY plane Bending torque in the Z plane Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 37 Wall mounted robot has a work area for axis 1 that depends on payload and the positions of other axes. Simulation in RobotStudio is recom- mended. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 38 Otherwise there is a risk that the robot stops or run with lower performance due to temperature dependent oil and grease viscosity. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 40: Safety Data
The SISTEMA/ABB FSDT libraries contains details for the safety functions. Performance level for OmniCore C30 for CRB 15000 The OmniCore C30 for CRB 15000 controller safety system has a safety category 3 with performance level PL d according to EN ISO 13849-1:2015 and thus fulfils the safety performance requirement of the robot safety standard EN ISO 10218-1:2011.
Page 41 Sufficient space must be provided around the robot to prevent an operator from being trapped. The falling distance and maximum speed are dependent on the robot pose, so this must be validated. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 42: Working Range
-90° -68° pos5 -507 -179 180° 22° pos6 -230.2 272.7 180° 85° pos7 -179 180° -158° pos8 198.1 287.6 180° -225° Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 43 Simulation in RobotStudio is re- commended. Axis 2 ±180° Axis 3 -225°/+85° Axis 4 ±180° Axis 5 ±180° Axis 6 ±270° Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 44: The Unit Is Sensitive To Esd
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. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 45: Installation And Commissioning
Safety on page 15 before performing any installation work. Note Always connect the CRB 15000 and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. For more information see: •...
Page 46: Unpacking
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.
Page 47: Risk Of Tipping/Stability
0° Axis 3 +85° Axis 4 0° Axis 5 0° Axis 6 0° WARNING The robot is mechanically unstable if not secured to the foundation. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 48: On-Site Installation
Introduction This procedure is a brief guide when installing the robot for the first time. Also see Pre-installation procedure on page First installation Use these procedures to install the CRB 15000. Action Note Transport the manipulator to its intended location.
Page 49: Lifting The Robot
30 Nm ±10% Length of thread engagement Minimum 15 mm for ground with material yield strength 150 MPa Level surface requirements 0.1/500 mm Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 50 This illustration shows the hole configuration used when securing the robot. + 0,012 6 H7 xx2000002366 Circular hole for locating pin Elongated hole for locating pin Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 51 Lifting and securing the robot Action Note CAUTION The CRB 15000 robot weighs 28 kg. A minim- um of two persons are required for lifting as well as securing the robot in order to avoid any damage, instability, and injury.
Page 52: Manually Releasing The Brakes
The holding brake on axis 6 can not be released manually. If axis 6 needs to be moved, release the holding brake on another proper axis instead. xx2000002539 xx2000002540 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 53 If any faulty functionality is dis- covered, see Brake release tool does not work on page 728. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 55: Installation Of Brake Release Tool
Securing the brake release tool holder Securing with screws xx2100000403 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 56 3 Installation and commissioning 3.3.4 Installation of brake release tool Continued Securing with cable ties xx2100000404 Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 57: Setting The System Parameters For An Inverted Or A Tilted Robot
If the robot is mounted on a wall (rotated around the x-axis), then the robot base frame and the system parameter Gravity Alpha must be redefined. The value of Gravity Alpha should then be ±π/2 (±1.570796). Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 58 Examples of mounting angles tilted around the X axis (Gravity Alpha) The following illustration shows the IRB 120, but the same principle applies for all robots. 0° xx2100000297 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 59 Robot, in the topic Motion. The system parameters are described in Technical reference manual - System parameters. The system parameters are configured in RobotStudio or on the FlexPendant. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 60: Loads Fitted To The Robot, Stopping Time And Braking Distances
The performance of the motor brake depends on if there are any loads attached to the robot. See Product specification - Robot stopping distances according to ISO 10218-1. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 61: Fitting Equipment On The Robot (Robot Dimensions)
• The brake release points on each axis must be accessible in the end application. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 62 7 x M6 xx2000002367 Fastener quality on tool flange Use screws with suitable length and tightening torque for your application. Screws with quality class 12.9 are recommended. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 63: Test Run After Installation, Maintenance, Or Repair
If maintenance or repair has been done, verify the function of the part that was main- tained. Verify the application in the operating mode manual reduced speed. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 64: Installation Of Laser Scanner
3.3.9 Installation of laser scanner Overview The safety separation technology and speed control for CRB 15000 is based on the connection and communication of one or two safety laser scanners in the robot. Laser scanner(s) provides a timely and continuous monitor on the activities within its scanning area and forms a protective field.
Page 65 OmniCore controller Laser Scanner1 white blue black brown PROFIsafe PROFIsafe 24V+ 0V Laser Scanner2 white blue black brown PROFIsafe 24V+ 0V xx2200000298 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 66 Scalable I/O device Laser Scanner 1 white blue black brown EtherNetIP 24V+ 0V Laser Scanner 2 white blue black brown 24V+ 0V xx2200000300 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 67 Reconfigure the PLC and laser scanner. See Configuration of one PROFINET- base laser scanner (RobotWare 7.5 or earlier) on page 101. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 68 Configuration of two PROFINET- base laser scanners (RobotWare 7.6 or later) on page 111 Configura- tion of two SafetyIO-base laser scanners (RobotWare 7.6 or later) on page 119. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 69: Electrical Connections
Robot cable Signal cable length Article number Hybrid floor cable 7 m 3HAC073212-002 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 70 Continued Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 71: Customer Connections On The Manipulator
Connectors at the base The R1.MP on the base is used for transferring DC bus, EtherCat and customer signals (CP/CS). xx2100000228 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 72 Plug with female connector includes housing and insert. xx2100000229 Connectors at the tool flange xx2100000125 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 73 (two pins for use, one pin is spare) M8x1 xx2100000220 M8 4 pin female, 200 mm 0.4 Nm Pin4 Pin2 wire, straight M10x0.75 Pin3 Pin1 M8x1 xx2100000219 Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 74: Arm-Side Interface
86, and Application manual - Functional safety and SafeMove. The tool and payload must be configured before configuring the arm-side interface. See Operating manual - OmniCore. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 75 On delivery, the light ring shows the states according to the following table: Color of the light ring State of the robot White Stand by Green Program running Yellow Lead through/programming mode Error Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 76 For more information on RAPID, see Technical reference manual - RAPID Instructions, Functions and Data types and Technical reference manual - RAPID Overview. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 77 2 Toggle the Enabled switch to turn on or off the light ring on the robot. 3 Inspect on which robot the light ring is affected. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 78: Using The Arm-Side Interface
The application ASI Setting on the FlexPendant must be open when using the buttons, if the buttons are configured differently than default. If the buttons are not responding, close the ASI Setting app and reopen it. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 79: Working Closely With The Robot In A Safe Way
Constrained collisions can be either transient, if the robot can give way (at least partially), or quasi-static. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 80 2 To prevent unexpected motion, initiated by additional clients: Do not add additional clients to the robot to control program execution. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 81 Finally, if risks in automatic mode cannot be sufficiently reduced by these or other means, use of the arm-side interface shall be restricted to manual mode. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 82: Configuring The Software
The configuration of emergency stops is stop category 1 and cannot be changed. Collision detection As default CRB 15000 will have collision detection active at stand still. It also has another stop ramp compared to other robots to be able to release clamping forces.
Page 83 3 Installation and commissioning 3.6.1 Information about software for the CRB 15000 Continued With the FlexPendant, a user can verify local presence with the three-position enabling device. For robots without a connected FlexPendant, system input signals can be used to verify local presence.
Page 84: Lead-Through
The Lead-through lock section is disabled for the Axis 1-6 mode. 4 Gently pull the robot arm to the desired position. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 85 If the load is lighter than the defined load, the effect will be the same as if you are pulling the robot arm upwards. For the CRB 15000, there is a button for updating/refreshing the load while lead-through is active.
Page 86: The Safemove Configurator App On Flexpendant
RobotStudio but the functionality is not as extensive. For more information about transient contact, quasi-static contact, and body areas, Guidelines for transient and quasi-static contact, CRB 15000 on page Overview of the user interface The user interface consists of a configurator and a 3D model that visualizes the robot with the configured encapsulations and zones.
Page 87 A sphere or capsule encapsulation can be modified in dimension and position. A lozenge capsule can be modified in dimension, position, and rotation. xx2100000712 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 88 6 Load the configuration to the safety controller. The robot controller is automatically restarted in this step. 7 Validate the configuration. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 89 1 Select Enable Edit Mode to edit the safety configuration. 2 Select Template configuration. xx2100000715 3 Review that the template configuration is suitable for the intended application. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 90 - Functional safety and SafeMove. 8 Apply the configuration to the controller. The controller is automatically restarted when applying the configuration. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 91 4 To add a supervision to a safe zone, tap to select the safe zone in the 3D view, then tap Add. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 92 6 When the supervision is applied, the data is transferred to Tool Speed Supervision and Tool Force Supervision. For more details, see Guidelines for transient and quasi-static contact, CRB 15000 on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E ©...
Page 93 The Standstill Supervision functionality is not active by default. It can be added, modified, and deactivated. The CRB 15000 has support for both stop category 0 and stop category 1 for Standstill Supervision. For other stops, only stop category 1 is available.
Page 94 The validation should verify that the following is configured correctly: • All I/O settings and signals used for safety interlocking including connected functionality • All Stop configuration functions Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 95 Running the robot in auto mode with the configuration unlocked will result in a warning message. 1 Log in as a user with the grant Lock Safety Controller Configuration. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 96 3 Select the check box Locked. Concluding steps After the validation is concluded, turn on the the SafeMove Assistant functionality, with the system parameter Disable SafeMove Assistant. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 97: Guidelines For Transient And Quasi-Static Contact, Crb 15000
3.6.4 Guidelines for transient and quasi-static contact, CRB 15000 About Human Contact Supervision The CRB 15000 robot is designed with collaborative applications in focus, where occasional contact between the human and the robot are foreseen. This is according to ISO/TS 15066.
Page 98 3 Installation and commissioning 3.6.4 Guidelines for transient and quasi-static contact, CRB 15000 Continued Body model As defined in ISO/TS 15066, the body model is a representation of the human body consisting of individual body segments characterized by biomechanical properties.
Page 99 3 Installation and commissioning 3.6.4 Guidelines for transient and quasi-static contact, CRB 15000 Continued Conclusion The values calculated in the Human Contact Supervision function are conservative. However, if the risk analysis for the final application shows that these values can...
Page 100: Information About Collaborative Speed Control Add-In
10 Select Apply to confirm and save the changes. The add-in is displayed in the controller overview if it is successfully added to the controller. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 101: Speed Control
Device Device slot mapping (default) ProtectingArea ProfiSafe OmniCore_Internal WarningArea ProfiSafe OmniCore_Internal ProtectingAreaSST ProfiSafe OmniCore_Internal WarningAreaTSP ProfiSafe OmniCore_Internal SafetyCommunica- ProfiSafe OmniCore_Internal tionEnable Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 102 RobotStudio or the OmniCore controller. • In the RobotWare installation folder in RobotStudio: ...\DistributionPackages\ABB.RobotWare-x.x.x-xxx\RobotPackages \RobotControl_x.x.xxx\utility\service\GSDML\ • On the OmniCore Controller: ...\products\RobotControl_x.x.x\utility\service\GSDML\ Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 103 Within this field range, the lamp unit turns to red and the robot movement speed is reduced to 0. The robot stands still. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 104 7 Create monitoring cases and assign the fields that are to be monitored to each monitoring cases in Configuration > Monitoring cases. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 105 1 Make some initial preparations. 2 Configure system parameters. 3 Set the input and output size and name of the PROFINET internal device. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 106 3 Installation and commissioning 3.6.6.1 Configuration of one PROFINET-base laser scanner (RobotWare 7.5 or earlier) Continued For CRB 15000, required settings for communication between laser scanner, PLC and OmniCore controller are predefined in the configuration file. 4 Set up safety user grants.
Page 107: Configuration Of One Profinet-Base Laser Scanner (Robotware 7.6 Or Later)
OmniCore_Internal WarningArea ProfiSafe OmniCore_Internal SafetyCommunica- ProfiSafe OmniCore_Internal tionEnable • The PROFINET device name of the controller must be set to omnicoreprofisafe. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 108 Within this field range, the lamp unit turns to red and the robot movement speed is reduced to 0. The robot stands still. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 109 3 and 2, respectively, and for the SDO are set to 5 and 4, respectively. • Make sure the address for the SDO signal is the first address of SDO 8 bytes slot. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 110 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 111: Configuration Of Two Profinet-Base Laser Scanners (Robotware 7.6 Or Later)
OmniCore_Internal WarningArea ProfiSafe OmniCore_Internal SafetyCommunica- ProfiSafe OmniCore_Internal tionEnable • The PROFINET device name of the controller must be set to omnicoreprofisafe. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 112 Within this field range, the lamp unit turns to red and the robot movement speed is reduced to 0. The robot stands still. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 113 Add the controller to the PLC by adding the DI 8 bytes, DO 8 bytes, SDI 8 bytes and SDO 8 bytes modules. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 114 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 115: Configuration Of One Safetyio-Base Laser Scanner (Robotware 7.6 Or Later)
Value of WarningArea depends on logic AND value of ABB_Scalable_IO_0_DI3 and ABB_Scalable_IO_0_DI4. For definition of WarningArea, see Configuring the laser scanner on page 116. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 116 2 Set IP address in Configuration > Addressing. Make sure the scanner IP address is in the same network segment with the PC used for configuring the scanner. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 117 3 Connect the logic power supply to connector X4 of the scalable I/O device via pin locations PWR and GND. 4 Connect the Ethernet cable from the robot controller to connector X5. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 118 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 119: Configuration Of Two Safetyio-Base Laser Scanners (Robotware 7.6 Or Later)
Value of WarningArea depends on logic AND value of ABB_Scalable_IO_0_DI3, ABB_Scalable_IO_0_DI4, ABB_Scalable_IO_0_DI7 and ABB_Scalable_IO_0_DI8. For definition of WarningArea, see Configuring the laser scanner on page 120. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 120 • Make sure the scanner IP addresses are in the same network segment with the PC used for configuring the scanner. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 121 1 Make sure that the laser scanner and scalable I/O device is connected as instructed in previous configuration procedure of laser scanner. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 122 7 Jog the robot to match the Actual Positions values with the Sync Positions values. Make sure the values are the same. 8 Tap Synchronize. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 123: Speed Control Strategies
3.6.6.6 Speed control strategies General The speed control of CRB 15000 is affected by several factors, such as, the RobotWare version, the speed setting in the FlexPendant, the speed setting in motion instruction and the SpeedRefresh value. Users in different protection fields defined for laser scanner to monitor and perform different program execution actions may result in different movement speed.
Page 124 3 Installation and commissioning 3.6.6.6 Speed control strategies Continued Users in Warning area xx2100000513 SafeMove triggered but SST/TSP not configured xx2100000514 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 125 3 Installation and commissioning 3.6.6.6 Speed control strategies Continued Strategies (RobotWare 7.6 or later) Users in Protecting area xx2200000302 Users in Warning area xx2200000303 Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 126: Use Cases Of Safety Configurations
SafeMove configurations also affect the speed control on the robot to achieve further safety. SafeMove is still functional after the SpeedHandling function in RAPID program is deactivated. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 127 Use the following procedure to change the speed limit based on risk assessment of the final application: 1 In RobotStudio, open the RAPID program InternalSpeedHandling_User in task T_ROB1. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 128 Configuration category. 4 In the left pane of the window, choose Global_TSP under the Tool Speed Supervisions from the navigation tree. xx2200000438 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 129 The change must be based on the risk assessment of the final application. 1 Open the RobotStudio. 2 Log in the controller using the Admin account and request the write access. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 130 6 Apply the configuration to the controller by clicking Write to Controller in the Controller group in the Configuration category. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 131: Maintenance
Note If the CRB 15000 is connected to power, always make sure that the CRB 15000 is connected to protective earth and a residual current device (RCD) before starting any maintenance work.
Page 132: Maintenance Schedule And Expected Component Life
4.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the CRB 15000: • Calendar time: specified in months regardless of whether the system is running or not.
Page 133: Maintenance Schedule
The inspection intervals do not specify the life of each component. Maintenance schedule Maintenance activities Reference Cleaning the CRB 15000 on page 140 Cleaning the robot Inspecting the robot on page 134 Inspecting the robot Inspecting the cable harness on...
Page 134: Inspection Activities
Checking the overall condition of the manipulator Action Note Look for abnormal wear or contamination. Clean as necessary. Cleaning the CRB 15000 on page 140. Check for loose hardware at robot arms, Tighten loose hardware at base (foundation base (foundation screws), and tool flange.
Page 135 Hex socket head cap screw 0.45 Nm M3x8 12.9 Lafre 2C2B/FC6.9 Housing inner plate Hex socket head cap screw 1.4 Nm M3x8 12.9 Lafre 2C2B/FC6.9 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 136 0.45 Nm M3x12 12.9 Lafre 2C2B/FC6.9 Tool flange Hex socket head cap screw 0.45 Nm M3x12 12.9 Lafre 2C2B/FC6.9 Base M10x35 8.8 30 Nm ±10% Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 137: Inspecting The Cable Harness
Spare part number Cable harness, base socket 3HAC073202-001 Cable harness, joint 1 3HAC073204-001 Cable harness, joint 2 3HAC073205-001 Cable harness, joint 3 3HAC073207-001 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 138 Inspecting the cable harness Action Note CAUTION Turn off all supplies for electrical power to the robot, before starting the repair work. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 139 CAUTION section Tightening torques to be inspected on page 135. Be careful not to squeeze any cabling during the refitting procedure. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 140: Cleaning Activities
4.4.1 Cleaning the CRB 15000 General To secure high uptime it is important that the CRB 15000 is cleaned regularly. The frequency of cleaning depends on the environment in which the manipulator works. Different cleaning methods are allowed depending on the type of protection of the CRB 15000.
Page 141: Testing Activities
• Look for damage to the magnet. Replace the tool if damaged. • See troubleshooting section Brake release tool does not work on page 728. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 142: Running The Cyclic Brake Check Routine
Use of such a configuration must be justified by risk assessment. • The method described in Brake testing on page 31 can be used to check that the brakes still function correctly. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 143: Testing The Functionality Of The Joint Electronics
Testing the joint electronics Action Note Turn off power to the controller and then turn the power on again. Verify that the robot starts as expected. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 144 This page is intentionally left blank...
Page 145: Repair
Individual subcomponents shall not be exchanged. Report replaced units Note When replacing a part on the CRB 15000, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 146: General Procedures
Do not try to grind or polish the shaft surface to get rid of the defect. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 147 Mount the sealing correctly with a mounting tool. Never hammer directly on the sealing as this may result in leakage. xx2000000072 A Gap Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 148 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 149: Cable Harness
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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E ©...
Page 150 • Axis 6: 0° xx2100000113 CAUTION Turn off all supplies for electrical power to the robot, before starting the repair work. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 151 Laying down the robot Action Note CAUTION The CRB 15000 robot weighs 28 kg. A minimum of two persons are required for lifting as well as securing the robot in order to avoid any damage, instability, and injury. Loosen the robot from the foundation.
Page 152 Disconnecting the base cabling Action Note Cut the cable ties. xx2100000424 Remove the functional and protective earth cables by removing the screw. xx2100000425 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 153 D1.DC- from ground xx2100000405 Removing the base cabling Action Note Remove the attachment screws. xx2100000406 Pull out the cabling from the base. xx2100000407 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 154 Secure the base connector with the attachment Hex socket head cap screw: M3x8 screws. 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm. xx2100000406 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 155 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2100000425 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 156 Wipe, lubricate and fit the o-ring to its groove. O-ring, nitrile rubber: 3HAB3772- Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002016 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 157 Lifting and securing the robot Action Note CAUTION The CRB 15000 robot weighs 28 kg. A minim- um of two persons are required for lifting as well as securing the robot in order to avoid any damage, instability, and injury.
Page 158 Concluding procedure Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 159: Replacing The Axis-1 Cabling
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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E ©...
Page 160 O-ring 3HAC061327-047 Cover for axis 2/3 Replace if damaged. Grease 3HAC042536-001 Shell Gadus S2 Cleaning agent Isopropanol Flange sealant Loctite 574 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 161 Removing the lower arm covers Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 163 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 164 Suggestion with lifting sling and an overhead crane: CAUTION The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 165 Remove the lower arm attachment screws. xx2000001940 Use two fully threaded attachment screws as re- moval tools to press the lower arm out of position. xx2000002151 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 166 Removing the swing cover Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 167 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 168 D2.X4 from X4 • D2.X2 from X2 • D2.X5 from X5 CAUTION Use tweezers to unlock connectors and pull them xx2000002013 off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 169 Use two screws as press out screws in the upcom- ing step, then dispose all screws. New screws are included in the spare part delivery of the joint unit. xx2000001943 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 170 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001958 Remove the lifting aid and guide pins. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 171 Loosening the base and removing the base cover Action Note Loosen the base from the foundation by removing the attachment screws and washers. xx2000002006 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 172 Remove the functional and protective earth cables by removing the screw. xx2000002011 Snap loose and disconnect the connectors: • J1.DC+ • J1.DC- • J1.CS • J1.CP xx2000002010 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 173 If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Cut the cable tie at the drive board. xx2000002058 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 174 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Remove the cable plate by removing the attach- ment screws. xx2000002049 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 175 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 176 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 177 Use the cable tie to pre-fix the cable by hand. xx2100000507 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 178 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 179 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2000002011 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 180 Wipe, lubricate and fit the o-ring to its groove. O-ring, nitrile rubber: 3HAB3772- Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002016 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 181 Attachment screws: M10x35 8.8 (4 foundation with the attachment screws and pcs). washers. Washers: 23/10.5/2.5 mm Steel (4 pcs). Tightening torque: 30 Nm ±10%. xx2000002006 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 182 M4x25 12.9 Lafre Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs) xx2000001987 Torque tighten all screws crosswise. Tightening torque: 4.6 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 183 Screws: M4x35 (4 pcs) The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 184 CAUTION xx2000001959 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001961 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 185 Torque tighten all screws crosswise. Tightening torque: 4.3 Nm. Remove the lifting aid by removing the screws. xx2000001956 Clean pushed-out flange sealant, if any. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 186 18 kg Lift the upper and lower arm assembly to mount- ing position and slide it onto the guide pins. xx2000001941 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 187 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000001939 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 188 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 189 Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 190 Refit the inner cover with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.4 Nm. xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 191 DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable. xx2000001932 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 192 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 193: Replacing The Axis-2 Cabling
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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E ©...
Page 194 Replace if damaged. O-ring, nitrile rubber 3HAB3772-64 Base cover Cleaning agent Isopropanol Flange sealant Loctite 574 Grease 3HAC042536-001 Shell Gadus S2 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 195 Removing the lower arm covers Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 197 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 198 Suggestion with lifting sling and an overhead crane: CAUTION The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 199 Remove the lower arm attachment screws. xx2000001940 Use two fully threaded attachment screws as re- moval tools to press the lower arm out of position. xx2000002151 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 200 Removing the swing cover Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 201 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 202 D2.X4 from X4 • D2.X2 from X2 • D2.X5 from X5 CAUTION Use tweezers to unlock connectors and pull them xx2000002013 off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 203 Use two screws as press out screws in the upcom- ing step, then dispose all screws. New screws are included in the spare part delivery of the joint unit. xx2000001943 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 204 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 205 Cut the cable tie at the drive board. xx2000002058 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 206 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 207 Tightening torque: 0.45 Nm. xx2000002049 Connect the two connectors to the torque sensor board. • TQ.A to CH1/A • TQ.B to CH2/B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 208 Keep the cabling loose, making sure not to twist or strain it. Use the cable tie to pre-fix the cable by hand. xx2100000507 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 209 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 210 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 211 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. xx2000002153 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 212 Remove the guide pins and secure the remaining two attachment screws. xx2100000295 Pre-tighten the screws crosswise. Torque tighten all screws crosswise. Tightening torque: 4.3 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 213 • J2.DC+ to J2.DC+ • J2.DC- to J2.DC- • J2.CS to J2.CS • J2.CP to J2.CP xx2000001944 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 214 Cable ties (3 pcs) xx2000001946 Refitting the swing cover Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-047 Replace if damaged. xx2000001962 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 215 Refit the cover with the four screws. Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 216 18 kg Lift the upper and lower arm assembly to mount- ing position and slide it onto the guide pins. xx2000001941 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 217 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000001939 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 218 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001936 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 219 Hex socket head cap screw: M3x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Secure the cover with four screws. Tightening torque: 0.45 Nm. xx2000001929 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 220 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 221: Replacing The Axis-3 Cabling
2 Remove the upper arm and place on a workbench. 3 Remove the housing cover. 4 Remove the axis-3 joint unit. 5 Replace the cabling. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 222 5.3.4 Replacing the axis-3 cabling 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 223 Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the four lower arm cover screws. xx2000001929 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 224 Remove the inner covers by removing the screws. xx2000001947 xx2000001930 Disconnecting the upper arm cabling Action Note Cut the cable ties. xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 225 Cut the cable tie. xx2000001965 Removing the upper arm Action Note Remove the cable bracket by removing the four screws. xx2000001966 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 226 Remove the remaining attachment screws. xx2000001969 Press the upper arm out of position by using two fully threaded attachment screws as removal tools. xx2100000001 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 227 Do not leave the cover in location without being secured with the attachment screws. Open the cover and cut the cable tie that holds the brake release cable. xx2000002022 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 228 Disconnecting the axis-3 joint unit cabling Action Note Cut the cable ties. xx2000002066 Remove the functional and protective earth cables by removing the screw. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 229 Remove two attachment screws. Dispose the screws. New screws are included in the spare part delivery of the joint unit. xx2000002070 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 230 Remove the joint unit from the housing. CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002071 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 231 If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Cut the cable tie at the drive board. xx2000002058 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 232 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Remove the cable plate by removing the attach- ment screws. xx2000002049 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 233 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 234 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 235 Use the cable tie to pre-fix the cable by hand. xx2100000507 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 236 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 237 Screws: M4x35 (4 pcs) The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 238 Always use new screws when refit- ting a joint unit. If ordering a new joint unit spare part, new screws are included. xx2100000320 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 239 • D3/4.DC+ to DC+ • D3/4.DC- to Ground • D3.X4 to X4 • D3/4.X2 to X2 • D3.X5 to X5 xx2000002068 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 240 (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002066 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 241 Orient the cover for proper arrangement of the brake release cable. xx2000002023 Secure the brake release cable with a cable tie. Cable ties xx2000002022 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 242 Apply flange sealant to the corner of the lower Flange sealant: Loctite 574 arm mounting surface, as pointed out in the figure. xx2000001973 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 243 Refit the cable bracket with the four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000001966 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 244 Connecting the upper arm cabling Action Note Connect the connectors to each other and snap them to the cable holders. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 245 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000001955 xx2000001954 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 246 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 247: Replacing The Axis-4 Cabling
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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E ©...
Page 248 If ordering a new axis-4 or axis-5 joint unit spare part, new screws for the tubular cover are included. Cleaning agent Isopropanol Flange sealant Loctite 574 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 249 Removing the housing cover Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000002021 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 250 Remove the cover. xx2000002023 Separating the cabling between the housing and the tubular Action Note Cut the cable ties. xx2000002066 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 251 • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002067 Disconnect the connectors from the drive board. • D3/4.X2 • D3/4.DC+ • D3/4.DC- xx2000002120 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 252 Removing the tubular Action Note Cut the cable tie. xx2000002077 Remove the cable bracket by removing the two screws. xx2000002078 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 253 Always use guide pins in pairs. xx2000002079 xx2000002080 Remove the remaining attachment screws. xx2000002081 Pull out the cabling carefully from the housing. xx2000002127 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 254 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 255 Dispose the screws. New screws must be used when refitting the cover. New screws are included in the spare part delivery of the joint unit. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 256 Remove the functional and protective earth cables by removing the screw. xx2000002087 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 257 Screws: M3x12 (4 pcs) CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002090 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 258 Remove the joint unit from the tubular. CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002116 sembly with care. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 259 If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Cut the cable tie at the drive board. xx2000002058 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 260 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Remove the cable plate by removing the attach- ment screws. xx2000002049 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 261 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 262 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 263 Use the cable tie to pre-fix the cable by hand. xx2100000507 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 264 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 265 Screws: M3x12 (4 pcs) The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 266 Remove the guide pins and secure the remaining two attachment screws. xx2000002091 Pre-tighten the screws crosswise. Torque tighten all screws crosswise. Tightening torque: 1.4 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 267 Reconnect the connectors to the drive board. • D3/4.X2 to X2 • D3/4.DC- to Ground • D3/4.DC+ to +DC xx2000002125 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 268 (1 pcs). Tightening torque: 0.8 Nm. xx2000002087 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002086 xx2000002124 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 269 Tightening torque: 1.6 Nm. xx2000002123 Refitting the axis-4 cover Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-051 Replace if damaged. xx2000002092 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 270 Action Note Fit two guide pins to the axis-4 joint. Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. xx2000002093 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 271 Remove the guide pins and fasten the remaining Flange socket head screw: M3x20 two screws. 12.9 Lafre 2C2B/FC6.9+PrO- COat111 xx2000002079 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 272 Cable ties (1 pcs) xx2000002077 Closing the housing top cover Action Note Check the inner plate gasket. Gasket: 3HAC075056-001 Replace if damaged. xx2000002095 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 273 Note Reconnect the connectors to the drive board. • D3/4.DC+ to DC+ • D3/4.DC- to Ground • D3/4.X2 to X2 xx2000002120 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 274 (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002066 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 275 Orient the cover for proper arrangement of the brake release cable. xx2000002023 Secure the brake release cable with a cable tie. Cable ties xx2000002022 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 276 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 277: Replacing The Axis-5 Cabling
4 Remove the axis-6 joint unit. 5 Remove the axis-5 cover. 6 Remove the axis-5 joint unit. 7 Replace the cabling. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 278 5.3.6 Replacing the axis-5 cabling 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 279 Dispose the screws. New screws must be used when refitting the cover. New screws are included in the spare part delivery of the joint unit. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 280 Open the cover and cut the cable tie that holds the brake release cable. xx2000002084 Disconnect the brake release connector DR.X8 Tweezers from the drive board. Remove the cover. xx2000002085 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 281 Remove the functional and protective earth cables by removing the screw. xx2000002087 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 282 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787- pins to the axis-5 joint unit. Always use guide pins in pairs. xx2000002128 xx2000002129 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 283 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 284 Disconnecting the tool flange functional earth cable Action Note Remove the functional earth cable by removing the screw. xx2000002159 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 285 Do not leave the arm-side interface in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 286 Disconnecting the axis-6 joint unit cabling Action Note Cut the cable ties. xx2000002161 Remove the functional and protective earth cables by removing the screw. xx2000002162 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 287 Position shown in the figure shows axis 5 jogged to +20°, which is a more convenient position when re- placing only the axis-6 joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 288 Use two screws as press out screws in the upcom- ing step, then dispose all screws. New screws are included in the spare part delivery of the joint unit. xx2100000329 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 289 Remove the lifting aid and guide pins. xx2000001957 Removing the axis-5 cover Action Note Remove the cover by removing the four screws. xx2000002132 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 290 Remove the cover. xx2000002134 Disconnecting the axis-5 joint unit cabling Action Note Cut the cable ties. xx2000002135 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 291 Screws: M3x12 (4 pcs) CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002139 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 292 Press the joint unit out of position using two of the previous attachment screws as removal tools. xx2100000334 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 293 Using the protection plate is important for protect- ing the drive board unit. If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 294 Remove the cable support from the drive board by removing the attachment screws. xx2000002055 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 295 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 296 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 297 Use the cable tie to pre-fix the cable by hand. xx2100000507 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 298 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 299 Screws: M3x12 (4 pcs) The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 300 Fit the transition cable between axis-5 and axis-6 Cable harness, transition joint-5 joint units into the tilt. and joint-6: 3HAC073209-001 xx2100000040 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 301 Always use new screws when refit- ting a joint unit. If ordering a new joint unit spare part, new screws are included. xx2100000333 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 302 • J5/6.DC+ to J6.DC+ • J5/6.DC- to J6.DC- • J5/6.CS to J6.CS • J5/6.CP to J6.CP xx2000002137 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 303 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 304 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. For joint units on axes 4, 5 and 6. xx2000002438 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 305 Always use new screws when refit- ting a joint unit. If ordering a new joint unit spare part, new screws are included. xx2100000329 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 306 • D6.DC+ to +DC • D6.DC- to Ground • D6.X4 to X4 • D6.X2 to X2 • D6.X5 to X5 xx2000002164 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 307 (1 pcs). Tightening torque: 0.8 Nm. xx2000002162 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002161 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 308 Refit the arm-side interface with four screws. Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000002550 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 309 Secure with screws. Flange socket head screw: M3x20 12.9 Lafre 2C2B/FC6.9+PrO- COat111 (16 pcs) Tightening torque: 1.8 Nm. xx2000002165 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 310 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002197 Place the tool flange at mounting position and reconnect the CP/CS connectors. xx2000002158 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 311 Hex socket head cap screw: M3x12 washers. 12.9 Lafre 2C2B/FC6.9 (10 pcs) Spring washer: 7x3.2x0.6 Steel (10 pcs) Tightening torque: 1.8 Nm. xx2000002155 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 312 Lift the tilt into mounting position while inserting the cabling into the tubular. Slide the tilt into place on the guide pins. xx2000002131 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 313 Reconnect the connectors to the drive board. • D3/4.X2 to X2 • D3/4.DC- to Ground • D3/4.DC+ to +DC xx2000002125 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 314 (1 pcs). Tightening torque: 0.8 Nm. xx2000002087 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002086 xx2000002124 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 315 Tightening torque: 1.6 Nm. xx2000002123 Refitting the axis-4 cover Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-051 Replace if damaged. xx2000002092 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 316 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 317: Replacing The Axis-6 Cabling
5 Replace the cabling. 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
Page 318 Jog the axis on which the joint unit is to be re- placed to home position, to achieve correct cable routing during replacement of the joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 319 Loosen the tool flange and remove the cable bracket by removing the screw. xx2000002156 Cut the cable ties. xx2000002157 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 320 Remove the tool flange adapter screws. xx2000002165 Press the adapter out of position by using two of the attachment screws as removal tools. xx2000002166 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 321 Remove the attachment screws. xx2000002550 Loosen the arm-side interface carefully and dis- connect the connectors from it. • ASI.DC+ • ASI.DC- • ASI.X1 xx2100000335 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 322 • D6.DC+ • D6.DC- • D6.X4 • D6.X2 • D6.X5 CAUTION Use tweezers to unlock connectors and pull them off. xx2000002164 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 323 Fit two guide pins to the axis-6 joint unit. Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. For joint units on axes 4, 5 and 6. xx2100000328 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 324 5 jogged to +20°, which is a more convenient position when re- placing only the axis-6 joint unit. Remove the lifting aid and guide pins. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 325 If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Cut the cable tie at the drive board. xx2000002058 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 326 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Remove the cable plate by removing the attach- ment screws. xx2000002049 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 327 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 328 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 329 Use the cable tie to pre-fix the cable by hand. xx2100000507 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 330 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 331 Screws: M3x12 (4 pcs) The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 332 CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002195 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 333 Torque tighten all screws crosswise. Tightening torque: 1.4 Nm. Remove the lifting aid by removing the screws. xx2000002168 Clean pushed-out flange sealant, if any. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 334 (1 pcs). Tightening torque: 0.8 Nm. xx2000002162 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002161 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 335 Refit the arm-side interface with four screws. Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000002550 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 336 Secure with screws. Flange socket head screw: M3x20 12.9 Lafre 2C2B/FC6.9+PrO- COat111 (16 pcs) Tightening torque: 1.8 Nm. xx2000002165 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 337 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002197 Place the tool flange at mounting position and reconnect the CP/CS connectors. xx2000002158 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 338 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 339: Replacing The Axis-5 To Axis-6 Transition Cabling
The replacement procedure is identical to replacing the axis-5 joint unit. Follow procedure Replacing the axis-5 joint unit and the axis-5 to axis-6 transition cabling on page 654. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 340: Replacing The Brake Release Unit
4 Replace the brake release unit. Axis-2/-3/-4/-5 brake release unit 1 Open the joint unit cover. 2 Replace the brake release unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 341 5.3.9 Replacing the brake release unit 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 342 Laying down the robot Action Note CAUTION The CRB 15000 robot weighs 28 kg. A minimum of two persons are required for lifting as well as securing the robot in order to avoid any damage, instability, and injury. Continues on next page...
Page 343 Remove the bottom cover by removing the attach- ment screws. xx2000002007 Removing the brake release unit Action Note Cut the cable tie. xx2100000410 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 344 Remove the brake release unit by removing the screws. xx2100000413 Remove the brake release cover by removing the two screws. xx2100000416 Remove the brake release board. xx2100000418 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 345 Harmonic Grease 4B No.2 Used to lubricate the seals. xx2100000419 If not already fitted, place the sheet metal inside the cover. xx2100000420 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 346 Fit the brake release cover and secure with two Screws: M2x6 12.9 Gleitmo 605 (2 screws. pcs) Tightening torque: 0.2 Nm. xx2100000416 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 347 Screws: M3x5 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm. xx2100000413 Reconnect the brake release connector DR.X8 to the drive board. xx2100000411 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 348 Wipe, lubricate and fit the o-ring to its groove. O-ring, nitrile rubber: 3HAB3772- Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002016 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 349 Lifting and securing the robot Action Note CAUTION The CRB 15000 robot weighs 28 kg. A minim- um of two persons are required for lifting as well as securing the robot in order to avoid any damage, instability, and injury.
Page 350 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 351 Disconnect the brake release connector DR.X8 from the drive board. Remove the cover. xx2000001932 Removing the brake release unit Action Note Cut the cable tie. xx2100000096 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 352 Remove the brake release cover by removing the two screws. xx2100000095 Disconnect the brake release cable from the board. xx2100000094 Remove the brake release board. xx2100000093 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 353 Fit the brake release board to the sheet metal. xx2100000093 Connect the brake release cable to the board. xx2100000094 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 354 Secure the cable with a cable tie. xx2100000096 Closing the joint unit cover Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-047 Replace if damaged. xx2000001962 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 355 Orient the cover for proper arrangement of the brake release cable. xx2000001932 Axis 3: xx2000002023 Axis 4: Tweezers xx2000002085 Axis 5: xx2000002134 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 356 Axis 4: 0.2 Nm Axis 5: 0.2 Nm xx2000001935 Concluding procedure Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 357: Upper And Lower Arms
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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E ©...
Page 358 Removing the lower arm covers Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 359 Remove the inner covers by removing the screws. xx2000001947 xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 360 Loosening the cabling between the lower and upper arm Action Note Remove the functional earth cable by removing the screw. xx2000001964 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 361 Fit two guide pins to the axis-3 joint unit. Guide pin, M4x120: 3HAC077786- Always use guide pins in pairs. xx2000001968 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 362 Removing the lower arm Action Note Remove the cable bracket by removing the four screws. xx2000001939 Secure the weight of the lower arm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 363 Remove the lower arm attachment screws. xx2000001940 Use two fully threaded attachment screws as re- moval tools to press the lower arm out of position. xx2000002151 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 364 Apply flange sealant to the corner of the lower Flange sealant: Loctite 574 arm mounting surface, as pointed out in the figure. xx2000001963 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 365 Hex socket head cap flange screw: two screws. M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) xx2000001951 Torque tighten all screws crosswise. Tightening torque: 4.6 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 366 Apply flange sealant to the corner of the lower Flange sealant: Loctite 574 arm mounting surface, as pointed out in the figure. xx2000001973 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 367 Refit the cable bracket with the four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000001966 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 368 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001936 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 369 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001964 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 370 Refit the inner covers with four screws each. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.4 Nm. xx2000001947 xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 371 Secure the cover with four screws. Tightening torque: 0.45 Nm. xx2000001929 Concluding procedure Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 372: Replacing The Housing
2 Remove the upper arm and place on a workbench. 3 Remove the axis-3 joint unit. 4 Remove the tubular. 5 Replace the housing. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 373 5.4.2 Replacing the housing 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 374 Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the four lower arm cover screws. xx2000001929 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 375 Remove the inner covers by removing the screws. xx2000001947 xx2000001930 Disconnecting the upper arm cabling Action Note Cut the cable ties. xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 376 Cut the cable tie. xx2000001965 Removing the upper arm Action Note Remove the cable bracket by removing the four screws. xx2000001966 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 377 Remove the remaining attachment screws. xx2000001969 Press the upper arm out of position by using two fully threaded attachment screws as removal tools. xx2100000001 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 378 Do not leave the cover in location without being secured with the attachment screws. Open the cover and cut the cable tie that holds the brake release cable. xx2000002022 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 379 Disconnecting the axis-3 joint unit cabling Action Note Cut the cable ties. xx2000002066 Remove the functional and protective earth cables by removing the screw. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 380 Remove two attachment screws. Dispose the screws. New screws are included in the spare part delivery of the joint unit. xx2000002070 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 381 Remove the joint unit from the housing. CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002071 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 382 Remove the cover by removing the four screws. xx2000002075 Remove the inner plate by removing the screws. xx2000002076 Removing the tubular Action Note Cut the cable tie. xx2000002077 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 383 Guide pin, M3x110: 3HAC077787- pins to the axis-4 joint unit. Always use guide pins in pairs. xx2000002079 xx2000002080 Remove the remaining attachment screws. xx2000002081 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 384 Place the tubular on a workbench. xx2000002082 Replace the housing Action Note Replace the housing. Housing: 3HAC073949-001 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 385 Lift the tubular into mounting position while insert- ing the cabling into the housing. Slide the tubular into place on the guide pins. xx2000002082 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 386 Refit the cable bracket with the two screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000002078 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 387 Refit the inner plate with the screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 1.4 Nm xx2000002076 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 388 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 389 CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002072 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 390 Torque tighten all screws crosswise. Tightening torque: 4.3 Nm. Remove the lifting aid by removing the screws. xx2000002069 Clean pushed-out flange sealant, if any. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 391 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 392 DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable. xx2000002023 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 393 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000002021 Refitting the upper arm Action Note Fit two guide pins to the axis-3 joint. xx2000001971 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 394 Hex socket head cap flange screw: two screws. M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) xx2000001967 Torque tighten all screws crosswise. Tightening torque: 4.6 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 395 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001964 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 396 Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 397 Refit the inner covers with four screws each. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (8 pcs) Tightening torque: 1.4 Nm. xx2000001947 xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 398 Calibrate the axis-3 joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 399: Replacing The Tubular
1 Separate the cabling between the housing and the tubular (at the axis-3 joint unit). 2 Remove the complete tubular. 3 Remove the axis-4 joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 400 5 Replace the tubular. 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
Page 401 Removing the housing cover Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 402 Open the cover and cut the cable tie that holds the brake release cable. xx2000002022 Disconnect the brake release connector DR.X8 from the drive board. Remove the cover. xx2000002023 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 403 Remove the functional and protective earth cables by removing the screw. xx2000001945 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002067 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 404 Opening the housing top cover Action Note Remove the cover by removing the four screws. xx2000002075 Remove the inner plate by removing the screws. xx2000002076 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 405 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787- pins to the axis-4 joint unit. Always use guide pins in pairs. xx2000002079 xx2000002080 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 406 Assist the cabling to be removed from the housing while lifting away the complete tubular. Place the tubular on a workbench. xx2000002082 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 407 Open the cover and cut the cable tie that holds the brake release cable. xx2000002084 Disconnect the brake release connector DR.X8 Tweezers from the drive board. Remove the cover. xx2000002085 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 408 Remove the functional and protective earth cables by removing the screw. xx2000002087 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 409 Screws: M3x12 (4 pcs) CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002090 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 410 Remove the joint unit from the tubular. CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002116 sembly with care. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 411 Remove the remaining attachment screws. xx2000002130 Press the tilt out of position using two of the pre- vious attachment screws as removal tools. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 412 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 413 Always use new screws when refit- ting a joint unit. If ordering a new joint unit spare part, new screws are included. xx2100000326 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 414 Note Reconnect the connectors to the drive board. • D4/5.X1 to X1 • D4/5.X4 to X4 • D4/5.X5 to X5 xx2000002088 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 415 Lift the tilt into mounting position while inserting the cabling into the tubular. Slide the tilt into place on the guide pins. xx2000002131 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 416 Reconnect the connectors to the drive board. • D3/4.X2 to X2 • D3/4.DC- to Ground • D3/4.DC+ to +DC xx2000002125 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 417 (1 pcs). Tightening torque: 0.8 Nm. xx2000002087 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002086 xx2000002124 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 418 Tightening torque: 1.6 Nm. xx2000002123 Refitting the axis-4 cover Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-051 Replace if damaged. xx2000002092 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 419 Action Note Fit two guide pins to the axis-4 joint. Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. xx2000002093 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 420 Remove the guide pins and fasten the remaining Flange socket head screw: M3x20 two screws. 12.9 Lafre 2C2B/FC6.9+PrO- COat111 xx2000002079 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 421 Cable ties (1 pcs) xx2000002077 Closing the housing top cover Action Note Check the inner plate gasket. Gasket: 3HAC075056-001 Replace if damaged. xx2000002095 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 422 Note Reconnect the connectors to the drive board. • D3/4.DC+ to DC+ • D3/4.DC- to Ground • D3/4.X2 to X2 xx2000002120 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 423 (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002066 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 424 Orient the cover for proper arrangement of the brake release cable. xx2000002023 Secure the brake release cable with a cable tie. Cable ties xx2000002022 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 425 Calibrate the axis-4 joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 426: Replacing The Wrist Housing
2 Separate the cabling between the tubular and the tilt (at the axis-4 joint unit). 3 Remove the tilt and place on a workbench. 4 Remove the axis-6 joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 427 6 Replace the wrist housing. 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
Page 428 Dispose the screws. New screws must be used when refitting the cover. New screws are included in the spare part delivery of the joint unit. xx2000002123 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 429 Open the cover and cut the cable tie that holds the brake release cable. xx2000002084 Disconnect the brake release connector DR.X8 Tweezers from the drive board. Remove the cover. xx2000002085 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 430 Remove the functional and protective earth cables by removing the screw. xx2000002087 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 431 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787- pins to the axis-5 joint unit. Always use guide pins in pairs. xx2000002128 xx2000002129 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 432 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 433 Disconnecting the tool flange functional earth cable Action Note Remove the functional earth cable by removing the screw. xx2000002159 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 434 Do not leave the arm-side interface in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 435 Disconnecting the axis-6 joint unit cabling Action Note Cut the cable ties. xx2000002161 Remove the functional and protective earth cables by removing the screw. xx2000002162 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 436 Position shown in the figure shows axis 5 jogged to +20°, which is a more convenient position when re- placing only the axis-6 joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 437 Use two screws as press out screws in the upcom- ing step, then dispose all screws. New screws are included in the spare part delivery of the joint unit. xx2100000329 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 438 Remove the lifting aid and guide pins. xx2000001957 Removing the axis-5 cover Action Note Remove the cover by removing the four screws. xx2000002132 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 439 Remove the cover. xx2000002134 Disconnecting the axis-5 joint unit cabling Action Note Cut the cable ties. xx2000002135 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 440 Screws: M3x12 (4 pcs) CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002139 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 441 Press the joint unit out of position using two of the previous attachment screws as removal tools. xx2100000334 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 442 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 443 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. For joint units on axes 4, 5 and 6. xx2000002438 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 444 CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002142 sembly with care. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 445 Torque tighten all screws crosswise. Tightening torque: 1.4 Nm. Remove the lifting aid by removing the screws. xx2000002139 Clean pushed-out flange sealant, if any. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 446 (1 pcs). Tightening torque: 0.8 Nm. xx2000002136 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002135 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 447 DR.X8 to the drive board. xx2000002134 Secure the brake release cable with a cable tie. Cable ties xx2000002133 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 448 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 449 For joint units on axes 4, 5 and 6. xx2000002438 Place the cabling at the slot before refitting the joint unit. xx2100000041 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 450 Remove the guide pins and secure the remaining two attachment screws. xx2000002170 Pre-tighten the screws crosswise. Torque tighten all screws crosswise. Tightening torque: 1.4 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 451 Connect the connectors to each other and snap them to the cable holders. • J7.CS to J7.CS • J7.CP to J7.CP xx2000002163 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 452 Cable ties (3 pcs) xx2000002161 Refitting the arm-side interface Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-051 Replace if damaged. xx2000002551 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 453 Apply flange sealant to the corner of the adapter Flange sealant: Loctite 574 mounting surface, as pointed out in the figure. xx2000002196 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 454 Connecting the tool flange functional earth cable Action Note Secure the cable for functional earth to the tool flange adapter with a screw. xx2000002159 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 455 Fit the connectors to the cable bracket and secure Cable ties (2 pcs) the connectors with two cable ties. xx2000002157 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 456 Action Note Fit two guide pins to the axis-5 joint. Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. xx2000002146 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 457 Flange socket head screw: M3x20 two screws. 12.9 Lafre 2C2B/FC6.9+PrO- COat111 (2 pcs) xx2000002128 Torque tighten all screws crosswise. Tightening torque: 1.8 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 458 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2000002087 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 459 Note Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-043 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002149 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 460 Calibrate the axis-5 and axis-6 joint unit torque Calibration on page 719 sensor. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 461: Replacing The Tool Flange And Axis-6 Inner Flange
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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E ©...
Page 462 Axis 5: No significance. • Axis 6: 0° CAUTION Turn off all supplies for electrical power to the robot, before starting the repair work. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 463 Loosen the tool flange and remove the cable bracket by removing the screw. xx2000002156 Cut the cable ties. xx2000002157 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 464 Remove the tool flange adapter screws. xx2000002165 Press the adapter out of position by using two of the attachment screws as removal tools. xx2000002166 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 465 Refit the tool flange adapter, aligning the pin with Axis-6 inner flange: 3HAC073952- the pin hole. xx2000002167 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 466 Check the o-ring on the tool flange and lubricate Axis-6 flange: 3HAC073953-001 with grease. O-ring: 3HAB3772-182 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002197 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 467 Refit the cable bracket with the screw. Hex socket head cap screw: M3x20 12.9 Lafre 2C2B/FC6.9 (1 pcs) Tightening torque: 0.8 Nm. xx2000002156 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 468 Spring washer: 7x3.2x0.6 Steel (10 pcs) Tightening torque: 1.8 Nm. xx2000002155 Concluding procedure Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 469: Replacing The Arm-Side Interface
The arm-side interface is located as shown in the figure. xx2000002549 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 470 Remove the attachment screws. xx2000002550 Loosen the arm-side interface carefully and dis- connect the connectors from it. • ASI.DC+ • ASI.DC- • ASI.X1 xx2100000335 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 471 Note Do not leave the arm-side interface in location xx2100000335 without being secured with the attachment screws. xx2100000336 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 472 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000002550 Concluding procedure Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 473: Swing And Base
6 Remove the axis-1 joint unit. 7 Replace the base. Move the base cabling and axis-1 brake release unit from old to new base. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 474 5.5.1 Replacing the base 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 475 CAUTION Turn off all supplies for electrical power to the robot, before starting the repair work. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 477 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 478 Suggestion with lifting sling and an overhead crane: CAUTION The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 479 Remove the lower arm attachment screws. xx2000001940 Use two fully threaded attachment screws as re- moval tools to press the lower arm out of position. xx2000002151 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 480 Removing the swing cover Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 481 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 482 D2.X4 from X4 • D2.X2 from X2 • D2.X5 from X5 CAUTION Use tweezers to unlock connectors and pull them xx2000002013 off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 483 Use two screws as press out screws in the upcom- ing step, then dispose all screws. New screws are included in the spare part delivery of the joint unit. xx2000001943 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 484 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001958 Remove the lifting aid and guide pins. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 485 Loosening the base and removing the base cover Action Note Loosen the base from the foundation by removing the attachment screws and washers. xx2000002006 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 486 Remove the functional and protective earth cables by removing the screw. xx2000002011 Snap loose and disconnect the connectors: • J1.DC+ • J1.DC- • J1.CS • J1.CP xx2000002010 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 487 Fit two guide pins to the axis-1 joint unit. Guide pin, M4x120: 3HAC077786- Always use guide pins in pairs. For joint units on axes 1, 2 and 3. xx2000002435 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 488 Remove the lifting aid and guide pins. xx2000001957 Removing the base cabling Action Note Remove the attachment screws. xx2100000406 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 489 Wipe, lubricate and fit the o-ring to its groove. O-ring, nitrile rubber: 3HAB3772- Replace if damaged. Grease: 3HAC031695-001 Harmonic Grease 4B No.2 Used to lubricate the seals. xx2100000423 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 490 Insert the cabling into the base. xx2100000408 Orient the base connector so that it points to the right, seen from back of the robot. xx2100000409 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 491 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 492 Always use new screws when refit- ting a joint unit. If ordering a new joint unit spare part, new screws are included. xx2000002008 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 493 • D1.DC- to Ground • D1.X4 to X4 • D1.X2 to X2 • D1.X5 to X5 • DR.X8 to X8 xx2000002009 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 494 (1 pcs). Tightening torque: 0.8 Nm. xx2000002011 Secure the cabling with cable ties. Cable ties (4 pcs) xx2000002012 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 495 Tightening torque: 1.2 Nm. Note Fit the cover in correct direction, the protrusion of the cover must face outwards. xx2000002007 xx2100000268 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 496 Apply flange sealant to the corner of the base Flange sealant: Loctite 574 mounting surface, as pointed out in the figure. xx2000001990 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 497 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 498 Screws: M4x35 (4 pcs) The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 499 CAUTION xx2000001959 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001961 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 500 Torque tighten all screws crosswise. Tightening torque: 4.3 Nm. Remove the lifting aid by removing the screws. xx2000001956 Clean pushed-out flange sealant, if any. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 501 18 kg Lift the upper and lower arm assembly to mount- ing position and slide it onto the guide pins. xx2000001941 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 502 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000001939 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 503 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 504 Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 505 Refit the inner cover with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.4 Nm. xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 506 DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable. xx2000001932 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 507 Calibrate the joint unit torque sensor for the axis-1 Calibration on page 719 and axis-2 joint units. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 508: Replacing The Swing
2 Remove the lower and upper arm undivided. 3 Remove the swing cover. 4 Remove the axis-2 joint unit. 5 Replace the swing. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 509 5.5.2 Replacing the swing 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 510 Removing the lower arm covers Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 512 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 513 Suggestion with lifting sling and an overhead crane: CAUTION The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 514 Remove the lower arm attachment screws. xx2000001940 Use two fully threaded attachment screws as re- moval tools to press the lower arm out of position. xx2000002151 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 515 Removing the swing cover Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 516 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 517 D2.X4 from X4 • D2.X2 from X2 • D2.X5 from X5 CAUTION Use tweezers to unlock connectors and pull them xx2000002013 off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 518 Use two screws as press out screws in the upcom- ing step, then dispose all screws. New screws are included in the spare part delivery of the joint unit. xx2000001943 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 519 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001958 Remove the lifting aid and guide pins. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 520 Lift away the swing. CAUTION The torque sensor (on the exposed PCBA) is sensitive to mechanical damage. Handle the as- sembly with care. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 521 M4x25 12.9 Lafre Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs) xx2000001987 Torque tighten all screws crosswise. Tightening torque: 4.6 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 522 Screws: M4x35 (4 pcs) The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 523 CAUTION xx2000001959 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001961 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 524 Torque tighten all screws crosswise. Tightening torque: 4.3 Nm. Remove the lifting aid by removing the screws. xx2000001956 Clean pushed-out flange sealant, if any. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 525 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 526 DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable. xx2000001932 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 527 Note Fit two guide pins to the axis-2 joint unit. Guide pin, M4x120: 3HAC077786- Always use guide pins in pairs. xx2000001949 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 528 Hex socket head cap flange screw: ment screws but two. M4x25 12.9 Lafre 2C2B/FC6.9+PrO-COat111 (16 pcs) Pre-tighten the screws crosswise firstly. xx2000001940 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 529 Connecting the cabling between the lower arm and swing Action Note Connect the connectors to each other and snap them to the cable holders. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 530 Note Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000001954 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 531 Calibrate the joint unit torque sensor for the axis-2 Calibration on page 719 joint unit. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 532: Joint Units
5 Loosen the base from the foundation and lay it down on its side. 6 Replace the axis-1 joint unit. Move the cabling from old to new joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 533 5.6.1 Replacing the axis-1 joint unit 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 534 Removing the lower arm covers Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 536 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 537 Suggestion with lifting sling and an overhead crane: CAUTION The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 538 Remove the lower arm attachment screws. xx2000001940 Use two fully threaded attachment screws as re- moval tools to press the lower arm out of position. xx2000002151 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 539 Removing the swing cover Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 540 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 541 D2.X4 from X4 • D2.X2 from X2 • D2.X5 from X5 CAUTION Use tweezers to unlock connectors and pull them xx2000002013 off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 542 Use two screws as press out screws in the upcom- ing step, then dispose all screws. New screws are included in the spare part delivery of the joint unit. xx2000001943 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 543 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001958 Remove the lifting aid and guide pins. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 544 Loosening the base and removing the base cover Action Note Loosen the base from the foundation by removing the attachment screws and washers. xx2000002006 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 545 Remove the functional and protective earth cables by removing the screw. xx2000002011 Snap loose and disconnect the connectors: • J1.DC+ • J1.DC- • J1.CS • J1.CP xx2000002010 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 546 Fit two guide pins to the axis-1 joint unit. Guide pin, M4x120: 3HAC077786- Always use guide pins in pairs. For joint units on axes 1, 2 and 3. xx2000002435 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 547 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 548 Cut the cable tie at the drive board. xx2000002058 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 549 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 550 Tightening torque: 0.45 Nm. xx2000002049 Connect the two connectors to the torque sensor board. • TQ.A to CH1/A • TQ.B to CH2/B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 551 Keep the cabling loose, making sure not to twist or strain it. Use the cable tie to pre-fix the cable by hand. xx2100000507 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 552 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 553 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 554 CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002015 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 555 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 556 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2000002011 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 557 Wipe, lubricate and fit the o-ring to its groove. O-ring, nitrile rubber: 3HAB3772- Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002016 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 558 Attachment screws: M10x35 8.8 (4 foundation with the attachment screws and pcs). washers. Washers: 23/10.5/2.5 mm Steel (4 pcs). Tightening torque: 30 Nm ±10%. xx2000002006 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 559 M4x25 12.9 Lafre Pre-tighten the screws crosswise firstly. 2C2B/FC6.9+PrO-COat111 (16 pcs) xx2000001987 Torque tighten all screws crosswise. Tightening torque: 4.6 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 560 Screws: M4x35 (4 pcs) The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 561 CAUTION xx2000001959 The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001961 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 562 Torque tighten all screws crosswise. Tightening torque: 4.3 Nm. Remove the lifting aid by removing the screws. xx2000001956 Clean pushed-out flange sealant, if any. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 563 18 kg Lift the upper and lower arm assembly to mount- ing position and slide it onto the guide pins. xx2000001941 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 564 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000001939 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 565 Secure the cables for functional earth and protect- Hex socket head cap screw: M3x6 ive earth with a screw. (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 566 Connect the connectors to each other and snap them to the cable holders. xx2000001938 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 567 Refit the inner cover with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 1.4 Nm. xx2000001930 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 568 DR.X8 to the drive board. Orient the cover for proper arrangement of the brake release cable. xx2000001932 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 569 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 570: Replacing The Axis-2 Joint Unit
2 Remove the lower and upper arm undivided. 3 Remove the swing cover. 4 Replace the joint unit. Move the cabling from old to new joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 571 5.6.2 Replacing the axis-2 joint unit 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 572 Removing the lower arm covers Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 574 Remove the functional earth cable by removing the screw. xx2000001936 Cut the cable ties. xx2000001937 Snap loose and disconnect all connectors. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 575 Suggestion with lifting sling and an overhead crane: CAUTION The weight of the complete upper and lower arm together is 18 kg xx2100000294 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 576 Remove the lower arm attachment screws. xx2000001940 Use two fully threaded attachment screws as re- moval tools to press the lower arm out of position. xx2000002151 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 577 Removing the swing cover Action Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the cover screws. xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 578 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 579 D2.X4 from X4 • D2.X2 from X2 • D2.X5 from X5 CAUTION Use tweezers to unlock connectors and pull them xx2000002013 off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 580 Use two screws as press out screws in the upcom- ing step, then dispose all screws. New screws are included in the spare part delivery of the joint unit. xx2000001943 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 581 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 582 Cut the cable tie at the drive board. xx2000002058 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 583 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 584 Tightening torque: 0.45 Nm. xx2000002049 Connect the two connectors to the torque sensor board. • TQ.A to CH1/A • TQ.B to CH2/B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 585 Keep the cabling loose, making sure not to twist or strain it. Use the cable tie to pre-fix the cable by hand. xx2100000507 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 586 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 587 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 588 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. xx2000002153 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 589 Remove the guide pins and secure the remaining two attachment screws. xx2100000295 Pre-tighten the screws crosswise. Torque tighten all screws crosswise. Tightening torque: 4.3 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 590 • J2.DC+ to J2.DC+ • J2.DC- to J2.DC- • J2.CS to J2.CS • J2.CP to J2.CP xx2000001944 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 591 Cable ties (3 pcs) xx2000001946 Refitting the swing cover Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-047 Replace if damaged. xx2000001962 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 592 Refit the cover with the four screws. Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000001935 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 593 18 kg Lift the upper and lower arm assembly to mount- ing position and slide it onto the guide pins. xx2000001941 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 594 Refit the cable bracket with four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000001939 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 595 Connect the functional earth cable with the screw. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (1 pcs). Tightening torque: 0.8 Nm xx2000001936 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 596 Hex socket head cap screw: M3x16 12.9 Lafre 2C2B/FC6.9 (4 pcs) Secure the cover with four screws. Tightening torque: 0.45 Nm. xx2000001929 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 597 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 598: Replacing The Axis-3 Joint Unit
2 Remove the upper arm and place on a workbench. 3 Remove the housing cover. 4 Replace the joint unit. Move the cabling from old to new joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 599 5.6.3 Replacing the axis-3 joint unit 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 600 Note CAUTION Make sure that all supplies for electrical power are turned off. Remove the four lower arm cover screws. xx2000001929 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 601 Remove the inner covers by removing the screws. xx2000001947 xx2000001930 Disconnecting the upper arm cabling Action Note Cut the cable ties. xx2000001937 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 602 Cut the cable tie. xx2000001965 Removing the upper arm Action Note Remove the cable bracket by removing the four screws. xx2000001966 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 603 Remove the remaining attachment screws. xx2000001969 Press the upper arm out of position by using two fully threaded attachment screws as removal tools. xx2100000001 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 604 Do not leave the cover in location without being secured with the attachment screws. Open the cover and cut the cable tie that holds the brake release cable. xx2000002022 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 605 Disconnecting the axis-3 joint unit cabling Action Note Cut the cable ties. xx2000002066 Remove the functional and protective earth cables by removing the screw. xx2000001945 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 606 Remove two attachment screws. Dispose the screws. New screws are included in the spare part delivery of the joint unit. xx2000002070 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 607 Remove the joint unit from the housing. CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002071 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 608 If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Cut the cable tie at the drive board. xx2000002058 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 609 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Remove the cable plate by removing the attach- ment screws. xx2000002049 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 610 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 611 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 612 Use the cable tie to pre-fix the cable by hand. xx2100000507 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 613 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 614 Screws: M4x35 (4 pcs) The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 615 Always use new screws when refit- ting a joint unit. If ordering a new joint unit spare part, new screws are included. xx2100000320 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 616 • D3/4.DC+ to DC+ • D3/4.DC- to Ground • D3.X4 to X4 • D3/4.X2 to X2 • D3.X5 to X5 xx2000002068 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 617 (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002066 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 618 Orient the cover for proper arrangement of the brake release cable. xx2000002023 Secure the brake release cable with a cable tie. Cable ties xx2000002022 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 619 Apply flange sealant to the corner of the lower Flange sealant: Loctite 574 arm mounting surface, as pointed out in the figure. xx2000001973 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 620 Refit the cable bracket with the four screws. Hex socket head cap screw: M3x8 12.9 Lafre 2C2B/FC6.9 (4 pcs). Tightening torque: 0.8 Nm xx2000001966 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 621 Connecting the upper arm cabling Action Note Connect the connectors to each other and snap them to the cable holders. xx2000001938 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 622 Wipe, lubricate and fit the o-ring to its groove. O-ring: 3HAC061327-044 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000001955 xx2000001954 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 623 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 624: Replacing The Axis-4 Joint Unit
2 Remove the tubular and place on a workbench. 3 Remove the axis-4 cover. 4 Replace the joint unit. Move the cabling from old to new joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 625 5.6.4 Replacing the axis-4 joint unit 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 626 Removing the housing cover Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 627 Open the cover and cut the cable tie that holds the brake release cable. xx2000002022 Disconnect the brake release connector DR.X8 from the drive board. Remove the cover. xx2000002023 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 628 Remove the functional and protective earth cables by removing the screw. xx2000001945 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002067 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 629 Opening the housing top cover Action Note Remove the cover by removing the four screws. xx2000002075 Remove the inner plate by removing the screws. xx2000002076 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 630 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787- pins to the axis-4 joint unit. Always use guide pins in pairs. xx2000002079 xx2000002080 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 631 Assist the cabling to be removed from the housing while lifting away the complete tubular. Place the tubular on a workbench. xx2000002082 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 632 Open the cover and cut the cable tie that holds the brake release cable. xx2000002084 Disconnect the brake release connector DR.X8 Tweezers from the drive board. Remove the cover. xx2000002085 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 633 Remove the functional and protective earth cables by removing the screw. xx2000002087 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 634 Screws: M3x12 (4 pcs) CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002090 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 635 Remove the joint unit from the tubular. CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- xx2000002116 sembly with care. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 636 If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Cut the cable tie at the drive board. xx2000002058 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 637 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Remove the cable plate by removing the attach- ment screws. xx2000002049 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 638 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 639 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 640 Use the cable tie to pre-fix the cable by hand. xx2100000507 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 641 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 642 Screws: M3x12 (4 pcs) The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 643 Remove the guide pins and secure the remaining two attachment screws. xx2000002091 Pre-tighten the screws crosswise. Torque tighten all screws crosswise. Tightening torque: 1.4 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 644 Reconnect the connectors to the drive board. • D3/4.X2 to X2 • D3/4.DC- to Ground • D3/4.DC+ to +DC xx2000002125 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 645 (1 pcs). Tightening torque: 0.8 Nm. xx2000002087 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002086 xx2000002124 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 646 Tightening torque: 1.6 Nm. xx2000002123 Refitting the axis-4 cover Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-051 Replace if damaged. xx2000002092 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 647 Action Note Fit two guide pins to the axis-4 joint. Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. xx2000002093 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 648 Remove the guide pins and fasten the remaining Flange socket head screw: M3x20 two screws. 12.9 Lafre 2C2B/FC6.9+PrO- COat111 xx2000002079 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 649 Cable ties (1 pcs) xx2000002077 Closing the housing top cover Action Note Check the inner plate gasket. Gasket: 3HAC075056-001 Replace if damaged. xx2000002095 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 650 Note Reconnect the connectors to the drive board. • D3/4.DC+ to DC+ • D3/4.DC- to Ground • D3/4.X2 to X2 xx2000002120 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 651 (1 pcs). Tightening torque: 0.8 Nm. xx2000001945 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002066 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 652 Orient the cover for proper arrangement of the brake release cable. xx2000002023 Secure the brake release cable with a cable tie. Cable ties xx2000002022 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 653 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 654: Replacing The Axis-5 Joint Unit And The Axis-5 To Axis-6 Transition Cabling
5.6.5 Replacing the axis-5 joint unit and the axis-5 to axis-6 transition cabling Location of the axis-5 joint unit The joint unit is located as shown in the figure. xx2000002121 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 655 7 Replace the axis-5 to axis-6 transition cabling. 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
Page 656 O-ring 3HAC061327-043 Tubular cover Replace if damaged. O-ring 3HAC061327-051 Axis-4 cover Replace if damaged. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 657 New screws are included in the spare part delivery of the joint unit. xx2000002123 Removing the axis-4 cover Action Note Remove the cover screws. xx2000002083 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 658 Open the cover and cut the cable tie that holds the brake release cable. xx2000002084 Disconnect the brake release connector DR.X8 Tweezers from the drive board. Remove the cover. xx2000002085 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 659 Remove the functional and protective earth cables by removing the screw. xx2000002087 Snap loose and disconnect the connectors: • J4/5.DC+ • J4/5.DC- • J4/5.CS • J4/5.CP xx2000002089 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 660 Remove two attachment screws and fit two guide Guide pin, M3x110: 3HAC077787- pins to the axis-5 joint unit. Always use guide pins in pairs. xx2000002128 xx2000002129 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 661 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 662 Disconnecting the tool flange functional earth cable Action Note Remove the functional earth cable by removing the screw. xx2000002159 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 663 Do not leave the arm-side interface in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 664 Disconnecting the axis-6 joint unit cabling Action Note Cut the cable ties. xx2000002161 Remove the functional and protective earth cables by removing the screw. xx2000002162 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 665 Position shown in the figure shows axis 5 jogged to +20°, which is a more convenient position when re- placing only the axis-6 joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 666 Use two screws as press out screws in the upcom- ing step, then dispose all screws. New screws are included in the spare part delivery of the joint unit. xx2100000329 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 667 Remove the lifting aid and guide pins. xx2000001957 Removing the axis-5 cover Action Note Remove the cover by removing the four screws. xx2000002132 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 668 Remove the cover. xx2000002134 Disconnecting the axis-5 joint unit cabling Action Note Cut the cable ties. xx2000002135 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 669 Screws: M3x12 (4 pcs) CAUTION The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000002139 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 670 Press the joint unit out of position using two of the previous attachment screws as removal tools. xx2100000334 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 671 Using the protection plate is important for protect- ing the drive board unit. If complete joint unit is to be replaced, the protection plate is not needed. xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 672 Remove the cable support from the drive board by removing the attachment screws. xx2000002055 Disconnect the two connectors from the torque sensor board. • TQ.A • TQ.B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 673 Orient the cable plate according to the figure. The circle on the cable plate should point towards the guide pin on the torque sensor. xx2000002051 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 674 Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (2 pcs) Tightening torque: 0.45 Nm. xx2000002055 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 675 Use the cable tie to pre-fix the cable by hand. xx2100000507 Fit the protection plate to the drive board unit. Protection plate: 3HAC077790-001 xx2000002057 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 676 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 677 Screws: M3x12 (4 pcs) The connectors and the joint unit cables are sensitive to mechanical damage. Handle the as- sembly with care. xx2000001957 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 678 Fit the transition cable between axis-5 and axis-6 Cable harness, transition joint-5 joint units into the tilt. and joint-6: 3HAC073209-001 xx2100000040 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 679 Always use new screws when refit- ting a joint unit. If ordering a new joint unit spare part, new screws are included. xx2100000333 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 680 • J5/6.DC+ to J6.DC+ • J5/6.DC- to J6.DC- • J5/6.CS to J6.CS • J5/6.CP to J6.CP xx2000002137 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 681 Cable ties (3 pcs) xx2000002135 Refitting the axis-5 cover Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-051 Replace if damaged. xx2000001962 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 682 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 683 Fit two guide pins to the joint unit. Guide pin, M3x110: 3HAC077787- Always use guide pins in pairs. For joint units on axes 4, 5 and 6. xx2000002438 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 684 Always use new screws when refit- ting a joint unit. If ordering a new joint unit spare part, new screws are included. xx2100000329 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 685 • D6.DC+ to +DC • D6.DC- to Ground • D6.X4 to X4 • D6.X2 to X2 • D6.X5 to X5 xx2000002164 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 686 (1 pcs). Tightening torque: 0.8 Nm. xx2000002162 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002161 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 687 Refit the arm-side interface with four screws. Hex socket head cap screw: M3x30 12.9 Lafre 2C2B/FC6.9 (4 pcs) Tightening torque: 0.45 Nm xx2000002550 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 688 Secure with screws. Flange socket head screw: M3x20 12.9 Lafre 2C2B/FC6.9+PrO- COat111 (16 pcs) Tightening torque: 1.8 Nm. xx2000002165 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 689 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000002197 Place the tool flange at mounting position and reconnect the CP/CS connectors. xx2000002158 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 690 Hex socket head cap screw: M3x12 washers. 12.9 Lafre 2C2B/FC6.9 (10 pcs) Spring washer: 7x3.2x0.6 Steel (10 pcs) Tightening torque: 1.8 Nm. xx2000002155 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 691 Lift the tilt into mounting position while inserting the cabling into the tubular. Slide the tilt into place on the guide pins. xx2000002131 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 692 Reconnect the connectors to the drive board. • D3/4.X2 to X2 • D3/4.DC- to Ground • D3/4.DC+ to +DC xx2000002125 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 693 (1 pcs). Tightening torque: 0.8 Nm. xx2000002087 Secure the cabling with cable ties. Cable ties (3 pcs) xx2000002086 xx2000002124 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 694 Tightening torque: 1.6 Nm. xx2000002123 Refitting the axis-4 cover Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-051 Replace if damaged. xx2000002092 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 695 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 696: Replacing The Axis-6 Joint Unit
2 Remove the tool flange adapter. 3 Remove the axis-6 cover. 4 Replace the joint unit. Move the cabling from old to new joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 697 5.6.6 Replacing the axis-6 joint unit 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 CRB 15000 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 698 Open the cover with care to avoid damage to the cabling or the connector(s). Do not leave the cover in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 699 Disconnecting the tool flange functional earth cable Action Note Remove the functional earth cable by removing the screw. xx2000002159 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 700 Do not leave the arm-side interface in location without being secured with the attachment screws. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 701 Disconnecting the axis-6 joint unit cabling Action Note Cut the cable ties. xx2000002161 Remove the functional and protective earth cables by removing the screw. xx2000002162 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 702 Position shown in the figure shows axis 5 jogged to +20°, which is a more convenient position when re- placing only the axis-6 joint unit. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 703 Use two screws as press out screws in the upcom- ing step, then dispose all screws. New screws are included in the spare part delivery of the joint unit. xx2100000329 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 704 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 705 Cut the cable tie at the drive board. xx2000002058 Remove the protection plate. xx2100000301 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 706 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 707 Tightening torque: 0.45 Nm. xx2000002049 Connect the two connectors to the torque sensor board. • TQ.A to CH1/A • TQ.B to CH2/B xx2000002053 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 708 Keep the cabling loose, making sure not to twist or strain it. Use the cable tie to pre-fix the cable by hand. xx2100000507 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 709 Assembly direction for the cable tie is shown in Cable tie gun EVO7 the figure. Settiing for cable tie gun: 6.75. xx2000002058 xx2000002059 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 710 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 711 For joint units on axes 4, 5 and 6. xx2000002438 Place the cabling at the slot before refitting the joint unit. xx2100000041 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 712 Remove the guide pins and secure the remaining two attachment screws. xx2000002170 Pre-tighten the screws crosswise. Torque tighten all screws crosswise. Tightening torque: 1.4 Nm. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 713 Connect the connectors to each other and snap them to the cable holders. • J7.CS to J7.CS • J7.CP to J7.CP xx2000002163 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 714 Cable ties (3 pcs) xx2000002161 Refitting the arm-side interface Action Note Fit the o-ring to its groove. O-ring: 3HAC061327-051 Replace if damaged. xx2000002551 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 715 Apply flange sealant to the corner of the adapter Flange sealant: Loctite 574 mounting surface, as pointed out in the figure. xx2000002196 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 716 Connecting the tool flange functional earth cable Action Note Secure the cable for functional earth to the tool flange adapter with a screw. xx2000002159 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 717 Fit the connectors to the cable bracket and secure Cable ties (2 pcs) the connectors with two cable ties. xx2000002157 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 718 Note Calibrate the joint unit torque sensor. Calibration on page 719 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 719: Calibration
6 Calibration 6.1 Calibration method and when to calibrate Calibration method The CRB 15000 torque sensors are calibrated with the routine TorqueSensorCal which is available in the System Module TorqueSensorCalib. No external calibration tools are required. The calibration method for the robot consists of calibrating the motor torque sensors, which are installed to monitor and measure the motor torque.
Page 720: Calibrating The Robot
System Module TorqueSensorCalib. No external calibration tools are required. The torque sensor calibration routine checks and calibrates the torque sensors of CRB 15000. This calibration routine must be run in manual operating mode. The torque sensor calibration routine checks and calibrates the torque sensors for the CRB 15000.
Page 721 5 If new calibration data is saved you will be asked to do a test with the lead-through functionality active to verify that the sensors work correctly. 6 Finally the robot is moved back to the original position. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 722: Jogging Directions
Illustration of axis jogging directions The figure shows the positive and negative directions for each axis when jogging the robot in the base coordinate system. xx2000002400 Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 723: Troubleshooting
Check: been installed • the configuration files • connectors • options and their configuration • changes in the robot working space/movements. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 724 The robot has recently Check: been moved from one site • connections to another (an already • software versions working robot) Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 725: Mechanical Noise Or Dissonance
Make sure the bearings are fitted correctly. Tighten the screws if a heat sink, fan, or metal sheet is loose. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 726 Investigate whether it chased from your local ABB representat- is possible to program small "cooling ive. periods" into the application. • Overpressure created inside gearbox. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 727: Manipulator Collapses On Power Down
Check the brake power supply to the col- See the circuit diagram. lapsing motor during the Motors OFF state. Check for any recorded fault status. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 728: Brake Release Tool Does Not Work
Check the brake power supply to the motor See the circuit diagram. during the Motors OFF state. Check for any recorded fault status. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 729 Five (5) attempts are allowed in total to reset the brake release. If desired, the process can be repeated from step 1. If the brake still does not release, contact the local ABB customer service. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 730: Communication Failure Between Profinet-Based Laser Scanner, Plc, And Controller
2 In the Controller tab page, choose Communication from the Configuration group. 3 Select Firewall Manager in the Type pane. 4 Set Enable on Public Network to Yes for the network service ProfiNet. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 731: Communication Failure Between Plc And Controller
Configuration group. 3 Check the Safe I/O configurations. For robots running RobotWare 7.5 or earlier, the following signals can be observed. xx2100000511 Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 732 5 Go back to the Visual SafeMove window and write the SafeMove configurations to the controller again. You will observe the signals and the communication is correctly set up. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 733: Communication Failure Between Scalable I/O Device And Controller
5 Go back to the Visual SafeMove window and write the SafeMove configurations to the controller again. You will observe the signals and the communication is correctly set up. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 734: Movement In Safe Area Not In Full Speed Or At Zero Speed
Reset the program pointer and start the program in the Safe area again. • Enter the Warning area but not trigger the TSP supervision violation and then back to the Safe area again. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 735: Unable To Remove Or Change Installed Options In Collaborative Speed Control Add-In
3 Remove the remained SpeedHandling modules in T_ROB1 if existing and remove the folder HOME/CSpeedControl manually. 4 Reset the RAPID and parameters in RobotStudio and restart the controller. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 736: Red Flashing Status On Scalable I/O Device And Unable To Move The Robot
If the serial number of the device is not 0, it is the right device requiring to be configured. 5 In the Configuration area, choose Update device and select ABB_Scalable_IO from the drop-down list. 6 Click OK. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 737: Unexpected Robot Movement When Starting The Program In Protecting Area
Reset the template SafeMove configuration file to factory setting and then load the configuration file provided with the Collaborative Speed Control add-in. See detailed procedures in The SafeMove configurator app on FlexPendant on page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
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Page 739: Decommissioning
8 Decommissioning 8.1 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
Page 740 China RoHS symbol The following symbol shows the information to hazardous substances and the environmental protection use period of CRB 15000 according to "Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products (SJ/T 11364-2014) ".
Page 741: Scrapping Of Robot
• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
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Page 743: Reference Information
9.1 Introduction 9 Reference information 9.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 744: Applicable Standards
Industrial robots and robot Systems - General safety require- ments EN ISO 10218-1 Robots and robotic devices — Safety requirements for indus- trial robots — Part 1: Robots Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 745 9 Reference information 9.2 Applicable standards Continued Deviations Deviations from ISO 10218-1:2011 for CRB 15000 The CRB 15000 is by default always in collaborative operation. Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 746: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 747: Screw Joints
9.4 Screw joints 9.4 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.
Page 748: Weight Specifications
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.
Page 749: Standard Toolkit
Hexagon bit socket head cap, size 2 mm Hexagon bit socket head cap, size 2.5 mm Hexagon bit socket head cap, size 3 mm Tweezer Cable ties Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 750: Special Tools
Special tools Note If the replacing procedure is not listed in the table below, only standard tools are needed for the procedure. Continues on next page Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 751 9 Reference information 9.7 Special tools Tools and equipment with spare part number: (These tools can be ordered from ABB) Lifting accessories Lifting aid 3HAC077788-001 xx2100000465 Lifting aid 3HAC077789-001 xx2100000464 Guiding tools Guide pin, M4x120 3HAC077786-001 xx2100000463 Guide pin, M3x110...
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Page 753 193 inspecting cabling, joint-1, 159 cable harness, 137 cabling, transition axis-5 to axis-6, 339, 654 robot, 134 cabling between robot and controller, 69 Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 754 38 protection class, 39 original spare parts, 15 protection types, 39 symbols, 19 technical data, 36 payload, 85 working range, 42 pedestal Robot Encapsulation Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 755 17 when to calibrate, 719 system integrator requirements, 26 working range, 43 system parameter robot, 42 Gravity Alpha, 58 wrist Gravity Beta, 57 replacing, 426 Product manual - CRB 15000 3HAC077389-001 Revision: E © Copyright 20212022 ABB. All rights reserved.
Page 758 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 20212022 ABB. All rights reserved. Specifications subject to change without notice.

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