Work Systematically - ABB IRC5 Operating Manual

2 Introduction to troubleshooting

2.3.2 Work systematically

2.3.2 Work systematically
Do not replace units randomly!
Before replacing any part at all, it is important to establish a probable cause for
the fault, thus determining which unit to replace.
Randomly replacing units may sometimes solve the acute problem, but also leaves
the troubleshooter with a number of units that may/may not be perfectly functional.
Replace one thing at a time!
When replacing a presumably faulty unit that has been isolated, it is important that
only one unit be replaced at a time.
Always replace components as detailed in the Repairs section of the Product
manual of the robot or controller at hand.
Test the system after replacing to see if the problem has been solved.
If replacing several units at once:
Take a look around!
Often, the cause may be evident once you see it. In the area of the unit acting
erroneously, be sure to check:
Check for tools left behind!
Some repair and maintenance work require using special tools to be fitted to the
robot equipment. If these are left behind (e.g. balancing cylinder locking device or
signal cable to a computer unit used for measuring purposes), they may cause
erratic robot behavior.
Make sure all such tools are removed when maintenance work is complete!
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• it is impossible to determine which of the units was causing the fault.
• it greatly complicates ordering a new spare part.
• it may introduce new faults to the system.
• Are the attachment screws secured?
• Are all connectors secured?
• Are all cabling free from damage?
• Are the units clean (especially for electronic units)?
• Is the correct unit fitted?
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Operating manual - Troubleshooting IRC5
3HAC020738-001 Revision: AA