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Product manual (part 1 of 2), procedures

Articulated robot
IRB 2400 - L
IRB 2400 - 10
IRB 2400 - 16
M2000,M2000A, M2004


Product manual, (part 1 of 2), procedures
Articulated robot
IRB 2400 - L
IRB 2400 - 10
IRB 2400 - 16
M2000
M2000A
M2004

Document ID: 3HAC 022031-001


Revision: A
The information in this manual is subject to change without notice and
should not be construed as a commitment by ABB. ABB assumes no
responsibility for any errors that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing
herein shall be construed as any kind of guarantee or warranty by ABB
for losses, damages to persons or property, fitness for a specific purpose
or the like.
In no event shall ABB be liable for incidental or consequential damages
arising from use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without
ABB’s written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention
will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then
current charge.

© Copyright 2004 ABB All right reserved.


ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Safety 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2.4.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3.4 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2 Installation and commissioning 41


2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2.1 Pre-installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2.2 Working range, IRB 2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3.1 Lifting manipulator with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3.3 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3.4 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.3.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.4.4 Limiting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3HAC 022031-001 Revision: A 3


Table of Contents

3 Maintenance 61
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2 Maintenace schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3 Changing activites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3.1 Change of oil in wrist unit IRB 2400/10/16 /L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3.2 Change the backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4 Repair 71
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3.1 Removal of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3.2 Refitting of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.4 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.4.1 Removal of wrist IRB 2400/10/16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.4.2 Refitting of wrist IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.4.3 Removal of wrist IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.4.4 Refitting of wrist IRB 2400L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.4.5 Removal of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.4.6 Reassemble of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.5 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.5.1 Removal of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.5.2 Refitting of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.5.3 Removal of the tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.5.4 Reassemble of the tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.6.1 Removal of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.6.2 Reassemble of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.6.3 Removal of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.6.4 Reassemble of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.6.5 Removal of the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.6.6 Reassemble of the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.7.1 Removal of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.7.2 Refitting of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.7.3 Removal of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.7.4 Refitting of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.7.5 Removal of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.7.6 Refitting of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.7.7 Removal of motor, axis 4-6;IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.7.8 Refitting of motor, axis 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.7.9 Removal of motor, axis 4-6, IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.7.10 Refitting of motor, axis 4-6 IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.8.1 Removal of gearbox, axis 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.8.2 Refitting of gearbox, axis 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.8.3 Remove the complete drive mechanism. IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4 3HAC 022031-001 Revision: A


Table of Contents

4.8.4 Refitting of complete drive mechanism. IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5 Calibration information 183


5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

3HAC 022031-001 Revision: A 5


Overview

Overview

About this manual


This manual contains instructions for
• mechanical and electrical installation of the manipulator
• maintenance of the manipulator
• mechanical and electrical repair of the manipulator.

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

Who should read this manual?


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

Prerequisites
The reader should...
• be a trained maintenance/repair craftsman
• have the required knowledge of mechanical and electrical installation/repair/
maintenance work.

Organization of chapters
The manual is organized in the following chapters:

Chapter Contents
Safety, service Safety information
Installation and commissioning Information about installation of the manipulator.
Maintenance Information about maintenance work, including
maintenance schedules.
Repair Information about repair work.
Calibration information Procedures that do not require specific calibration
equipment. General information about calibration.
Decommissioning Environmental information about the manipulator.

6 3HAC 022031-001 Revision: A


Overview

References

Reference Document Id

Revisions

Revision Description
- First edition.
Replaces previous manuals:
• Installation and Commssioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Model M2004 implemented.
A Chapter“ Calibration” replaced with chapter “Calibration information”.
Safety chapter rewritten.

3HAC 022031-001 Revision: A 7


How to read the product manual

How to read the product manual

Reading the procedures


The procedures contain references to figures, tools, material etc. The references are read as
described below.

References to figures
The procedures often include references to components or attachment points located on the
robot/controller. The components or attachment points are marked with italic text in the
procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in an procedure.

Step Action Note/Illustration


8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.

References to required equipment


The procedures often include references to equipment (spare parts, tools etc.) required for the
different actions in the procedure. The equipment is marked with italic text in the procedures
and completed with a reference to the section where the equipment is listed with further
information, i.e. article number, dimension.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced list.
The table below shows an example of a reference to a list of required equipment, from a step
in an procedure.

Step Action Note/Illustration


3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.

Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed. Read more in chapter Safety on page
13.

8 3HAC 022031-001 Revision: A


Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:

Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams

Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.

Controller hardware option manual


Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.

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Product documentation, M2004

Product documentation, M2004

General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.

Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams

RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
• RAPID Overview: An overview of the RAPID programming language.
• RAPID reference manual part 1: Description of all RAPID instructions.
• RAPID reference manual part 2: Description of all RAPID functions and data types.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.

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

10 3HAC 022031-001 Revision: A


Product documentation, M2004

• How to use the application


• Examples of how to use the application

Operator’s manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
• Operator’s manual - IRC5 with FlexPendant
• Operator’s manual - RobotStudioOnline
• Trouble shooting Manual for the controller and robot

Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
• Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)

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Product documentation, M2004

12 3HAC 022031-001 Revision: A


1 Safety
1.1. Introduction

1 Safety
1.1. Introduction

Overview
The safety information in this manual is divided in two categories:
• general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in section General
safety information on page 14.
• specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 34.

3HAC 022031-001 Revision: A 13


1 Safety
1.2.1. Introduction

1.2 General safety information

1.2.1. Introduction

Definitions
This section details general safety information for service personnel i.e. personnel performing
installation, repair and maintenance work.

Sections
The general safety information is divided into the following sections:
1. General information contains lists of:
• Safety, service
• Limitation of liability
• Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split
into different categories:
• Safety risks during service work on robot
• Safety risks related to gripper/end effector
• Safety risks related to tools/workpieces
• Safety risks related to pneumatic/hydraulic systems
• Safety risks during operational disturbances
• Safety risks during installation and service
• Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
• Safety fence dimensions
• Fire extinguishing
• Emergency release of the manipulator´s arm
• Brake testing
• Risk of disabling function "Reduced speed 250 mm/s"
• Safe use of the Teach Pendant Unit enabling device
• Work inside the manipulator´s working range
• Signal lamp (optional)

14 3HAC 022031-001 Revision: A


1 Safety
1.2.2.1. Safety, service

1.2.2. General information

1.2.2.1. Safety, service

Validity and responsibility


The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, e.g. User’s Guide and Product
Manual.

Connection of external safety devices


Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for
connecting safety devices between the robot and the peripheral equipment.

3HAC 022031-001 Revision: A 15


1 Safety
1.2.2.2. Limitation of Liability

1.2.2.2. Limitation of Liability

General
Any information given in this manual regarding safety, must not be construed as a warranty
by ABB that the industrial robot will not cause injury or damage even if all safety instructions
have been complied with.

16 3HAC 022031-001 Revision: A


1 Safety
1.2.2.3. Related information

1.2.2.3. Related information

General
The list below specifies documents which contain useful information:

Documents

Type of information Detailed in document Section


Installation of safety devices Product manual for the Installation and commissioning
manipulator
Changing robot modes User’s Guide Start-up
Restricting the working space Product manual for the Installation and commissioning
manipulator

3HAC 022031-001 Revision: A 17


1 Safety
1.2.3.1. Safety risks during service work on robot

1.2.3. Safety risks

1.2.3.1. Safety risks during service work on robot

Overview
This section includes information of general safety risks to be considered when performing
service work on the robot.

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1 Safety
1.2.3.1. Safety risks during service work on robot

Complete robot

Safety risk Description


Hot components!

Caution!

Motors and gears are HOT after running the robot!


Touching the motors and gears may result in burns!
Removed parts may result in
collaps of robot!

Warning!

Take any necessary measures to ensure that the robot


does not collapse as parts are removed, e.g. secure the
lower arm with fixtures if removing motor, axis 2.

Cabling

Safety risk Description


Cable packs are sensitive to
mechanical damage!

Caution!

The cable packs are sensitive to mechanical damage!


They must be handled with care, especially the
connectors, in order to avoid damaging them!

Gearboxes and motors

Safety risk Description


Gears may be damaged if
excessive force is used!

Caution!

Whenever parting/mating motor and gearbox, the gears


may be damaged if excessive force is used!

3HAC 022031-001 Revision: A 19


1 Safety
1.2.3.1. Safety risks during service work on robot

Balancing device

Safety risk Description


Dangerous balancing device!

Warning!

Do not under any circumstances, deal with the balancing


device in any other way than that detailed in the product
documentation! For example, attempting to open the
balancing device is potentially lethal!

20 3HAC 022031-001 Revision: A


1 Safety
1.2.3.2. Safety risks related to gripper

1.2.3.2. Safety risks related to gripper

CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.

3HAC 022031-001 Revision: A 21


1 Safety
1.2.3.3. Safety risks related to tools/workpieces

1.2.3.3. Safety risks related to tools/workpieces

Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).

Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.

22 3HAC 022031-001 Revision: A


1 Safety
1.2.3.4. Safety risks related to pneumatic/hydraulic systems

1.2.3.4. Safety risks related to pneumatic/hydraulic systems

General
Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy
• Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.

Safe design
• Gravity may cause any parts or objects held by these systems to drop.
• Dump valves should be used in case of emergency.
• Shot bolts should be used to prevent tools, etc., from falling due to gravity.

3HAC 022031-001 Revision: A 23


1 Safety
1.2.3.5. Safety risks during operational disturbances

1.2.3.5. Safety risks during operational disturbances

General
• The industrial robot is a flexible tool which can be used in many different industrial
applications.
• All work must be carried out professionally and in accordance with the applicable
safety regulations.
• Care must be taken at all times.

Qualified personnel
• Remedial action must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.

Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other than those
associated with regular operation. Such an interruption may have to be rectified manually.

24 3HAC 022031-001 Revision: A


1 Safety
1.2.3.6. Safety risks during installation and service

1.2.3.6. Safety risks during installation and service

General risks during installation and service


• The instructions in the Product Manual - Installation and Commissioning must always
be followed.
• Emergency stop buttons must be positioned in easily accessible places so that the robot
can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are available for
the installation in question.
• Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.

Nation/region specific regulations


To prevent injuries and damage during the installation of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.

Non-voltage related risks


• Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
• Turntables or the like should be used to keep the operator out of the robot's working
space.
• The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
parallel arm.
• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, is dismantled.
• When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored heat energy in the controller.
• Never use the robot as a ladder, i.e. do not climb on the robot motors or other part
during service work. There is a serious risk of slipping because of the high temperature
of the motors or oil spills that can occur on the robot.

To be observed by the supplier of the complete system


• The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.

3HAC 022031-001 Revision: A 25


1 Safety
1.2.3.7. Risks associated with live electric parts

1.2.3.7. Risks associated with live electric parts

Voltage related risks, general


• Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
• The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot’s working space.

Voltage related risks, controller


A danger of high voltage is associated with the following parts:
• Be aware of stored electrical energy (DC link) in the controller.
• Units inside the controller, e.g. I/O modules, can be supplied with power from an
external source.
• The mains supply/mains switch
• The power unit
• The power supply unit for the computer system (230 VAC)
• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
• The drive unit (700 VDC)
• The service outlets (115/230 VAC)
• The power supply unit for tools, or special power supply units for the machining
process
• The external voltage connected to the control cabinet remains live even when the robot
is disconnected from the mains.
• Additional connections

Voltage related risks, robot


A danger of high voltage is associated with the robot in:
• The power supply for the motors (up to 800 VDC)
• The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)

Voltage related risks, tools, material handling devices, etc


Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be
damaged.

26 3HAC 022031-001 Revision: A


1 Safety
1.2.4.1. Safety fence dimensions

1.2.4. Safety actions

1.2.4.1. Safety fence dimensions

General
Install a safety cell around the robot to ensure safe robot installation and operation.

Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.

3HAC 022031-001 Revision: A 27


1 Safety
1.2.4.2. Fire extinguishing

1.2.4.2. Fire extinguishing

NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator
or controller)!

28 3HAC 022031-001 Revision: A


1 Safety
1.2.4.3. Emergency release of the robot’s arm

1.2.4.3. Emergency release of the robot’s arm

Description
In an emergency situation, any of the robot’s axes may be released manually by pushing the
brake release buttons on the robot or on an optional external brake release unit.
How to release the brakes is detailed in section:
• Manually releasing the brakes on page 47.
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.

Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!

3HAC 022031-001 Revision: A 29


1 Safety
1.2.4.4. Brake testing

1.2.4.4. Brake testing

When to test
During operation the holding brakes of each axis motor wear normally. A test may be
performed to determine whether the brake can still perform its function.

How to test
The function of each axis’ motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator
arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the
controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.

30 3HAC 022031-001 Revision: A


1 Safety
1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s"

1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s"

NOTE!
Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant
Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.

3HAC 022031-001 Revision: A 31


1 Safety
1.2.4.6. Safe use of the Teach Pendant Unit

1.2.4.6. Safe use of the Teach Pendant Unit

NOTE!
The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)
which, when pressed halfway in, takes the system to MOTORS ON. When the enabling
device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
• The enabling device must never be rendered inoperative in any way.
• During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
• The programmer must always bring the Teach Pendant Unit with him/her, when
entering the robot's working space. This is to prevent anyone else taking control over
the robot without the programmer knowing.

32 3HAC 022031-001 Revision: A


1 Safety
1.2.4.7. Work inside the manipulator’s working range

1.2.4.7. Work inside the manipulator’s working range

WARNING!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
• The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in
position < 250 mm/s. This should be the normal position when entering the working
space. The position 100% ”full speed” may only be used by trained personnel who are
aware of the risks that this entails.
• Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in
order not to get entangled with hair or clothing. Also be aware of any danger that may
be caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
• Test the motor brake on each axis, according to section Brake testing on page 30.

3HAC 022031-001 Revision: A 33


1 Safety
1.3.1. Safety signals, general

1.3 Safety related instructions

1.3.1. Safety signals, general

General
This section specifies all dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
• A brief description of what will happen if the operator/service personnel does not
eliminate the danger.
• An instruction of how to eliminate the danger to facilitate performing the activity at
hand.

Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.

Symbol Designation Signification


DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
danger impact, fall from height etc.
WARNING Warns that an accident may occur if the instructions
are not followed, that can lead to serious injury,
possibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk of
warning crushing, impact, fall from height etc.
ELECTRICAL The electrocution or electrical shock symbol
SHOCK indicates electrical hazards which could result in
severe personal injury or death.

Electrical shock

CAUTION Warns that an accident may occur if the instructions


are not followed, that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height etc. Furthermore, it applies to
caution warnings that include function requirements when
fitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.

34 3HAC 022031-001 Revision: A


1 Safety
1.3.1. Safety signals, general

Symbol Designation Signification


ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates
DISCHARGE (ESD) electrostatic hazards which could result in severe
damage to the product.

Electrostatic discharge
(ESD)

NOTE Note symbols alert you to important facts and


conditions.

Note

TIP Tip symbols direct you to specific instructions, where


to find additional information or how to perform a
certain operation in an easier way.

Tip

3HAC 022031-001 Revision: A 35


1 Safety
1.3.2. DANGER - Moving manipulators are potentially lethal!

1.3.2. DANGER - Moving manipulators are potentially lethal!

Description
Any moving manipulator is a potentially lethal machine.
When running the manipulator, it may perform unexpected and sometimes irrational
movements. However, all movements are performed with great force and may seriously
injure any personnel and/or damage any piece of equipment located within the manipulator
working range.

Elimination

Step Action Info/Illustration


1. Before attempting to run the manipulator, Emergency stop equipment such as
make sure all emergency stop equipment gates, tread mats, light curtains, etc.
has been correctly installed and connected.
2. If possible, use the hold-to-run button How to use the hold-to-run control in
whenever possible. RobotWare 5.0 is detailed in section
The hold-to-run button is used in manual How to use the hold-to-run switch in
mode, not in automatic mode. the Operator’s Manual, IRC5.
How to use the hold-to-run control in
RobotWare 4.0 is detailed in section
The Teach Teach Pendant unit in the
User’s Guide.
3. Make sure no personnel is present within
the manipulator working range before
pressing the start button.

36 3HAC 022031-001 Revision: A


1 Safety
1.3.3. WARNING - The unit is sensitive to ESD!

1.3.3. WARNING - The unit is sensitive to ESD!

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

Elimination

Step Action Note/Illustration


1. Use a wrist strap Wrist straps must be tested frequently to
ensure that they are not damaged and are
operating correctly.
2. Use an ESD protective floor mat. The mat must be grounded through a current-
limiting resistor.
3. Use a dissipative table mat. The mat should provide a controlled discharge
of static voltages and must be grounded.

Assemble the wrist strap


The picture illustrates how the ESD wrist strap is assembled in the controller cabinet.

xx0400001055

A The strap is fastened to a button on the side of the control cabinet.


B When not used, the wrist strap is placed on the power supply unit.
C Power supply unit

3HAC 022031-001 Revision: A 37


1 Safety
1.3.4. WARNING - Safety risks during work with gearbox oil

1.3.4. WARNING - Safety risks during work with gearbox oil

Description
When handling the gearbox oil, there are several dangers to both personal injuries and product
damages! Following safety information must be regarded before performing any work with
the oil in the gearboxes!

Warnings and elimination

Warning Description Elimination / Action


Changing and draining Make sure that protective gear
gearbox oil may require like goggles and gloves are
handling hot oil of up to 90 °C! always worn during this activity.

Hot oil!
When opening the oil plug, Open oil plug carefully and keep
there may be pressure present away from the opening. Do not
in the gearbox, causing oil to overfill the gearbox when filling.
spray from the opening!

Possible pressure build


up in gearbox!
Overfilling of gearbox oil can Make sure not to overfill the
lead to internal over-pressure gearbox when filling with oil!
inside the gearbox which in After filling, check the correct oil
turn may: levels as described in section .
• damage seals and
-
gaskets
Do not overfill! • completely press out
seals and gaskets
• prevent the manipulator
from moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the mix different types of oil unless
gearbox! specified in the instruction.
Always use the type of oil
specified by the manufacturer!
-

Do not mix types of oil!

38 3HAC 022031-001 Revision: A


1 Safety
1.3.4. WARNING - Safety risks during work with gearbox oil

Warning Description Elimination / Action


Warm oil drains quicker than When changing gearbox oil, first
cold oil. run the robot for a time to heat
up the oil.

Heat up the oil!


The specified amount of oil is After refilling, check the oil level
based on the total volume of as described in section .
the gearbox. When changing
the oil, the amount of refilled oil
may differ from the specified
- amount, depending on how
much oil has previously been
Specified amount
drained from the gearbox.
depends on drained
volume!

3HAC 022031-001 Revision: A 39


1 Safety
1.3.4. WARNING - Safety risks during work with gearbox oil

40 3HAC 022031-001 Revision: A


2 Installation and commissioning
2.1. Introduction

2 Installation and commissioning


2.1. Introduction

General
This chapter contains information for installing the robot to the working site.
More detailed technical data, such as load diagram, permitted extra loads (equipment) and
location of extra loads (equipment), may be found in the Product Specification for the robot.

3HAC 022031-001 Revision: A 41


2 Installation and commissioning
2.2.1. Pre-installation procedure

2.2 Unpacking

2.2.1. Pre-installation procedure

General
These instructions are to be used when unpacking and installing the robot for the first time.
They also contain information useful later during re-installation of the manipulator.

Checking the pre-requisites for installation


The check-list below details what must be observed before proceeding with the actual
installation of the manipulator:
1. Make sure only qualified installation personnel conforming to all national and local codes
are allowed to perform the installation.
2. Make sure the manipulator is not damaged, by visually inspecting it.
3. Make sure the lifting device to be used is fit to handle the weight of the manipulator as
specified in Weight on page 42.
4. If the manipulator is not to be installed directly, it must be stored as described in Storage
conditions on page 43.
5. Make sure the appointed operating environment of the manipulator conforms to the
specifications outlined in Operating conditions on page 43.
6. Before taking the manipulator to the installation site, make sure the site conforms to Loads
on foundation on page 42, Requirements on foundation on page 43 and Protection classes
on page 43.
7. When these prerequisites are met, the manipulator may be taken to its installation site as
described in Lifting manipulator with lifting slings on page 46.

Weight
The net weight of the manipulator is approximately: 380 kg.

Loads on foundation
The table below shows the different forces and torques working on the manipulator during
various kinds of operation.
Note! These forces and torques are extreme values that are rarely encountered during
operation. The values also never simultanesously reach their maximum!

IRB 2400 -10, -16

Endurance load Max. load (emergency


Forces and torques
(operation) stop)
Force xy (upright/ ± 2000 N ± 2600 N
suspended)
Force z (upright) 4100 ± 1400 N 4100 ± 1900 N
Forze z (suspended) - 4100 ± 1400 N - 4100 ± 1900 N
Torque Mxy ± 3400 Nm ± 4000 Nm
Torque Mz ± 550 Nm ± 900 Nm

42 3HAC 022031-001 Revision: A


2 Installation and commissioning
2.2.1. Pre-installation procedure

IRB 2400 - L

Endurance load Max. load (emergency


Forces and torques
(operation) stop)
Force xy ± 1700 N ± 2100 N
Force z, upright 4100 ± 1100 N 4100 ± 1400 N
Force z, suspended - 4100 ± 1100 N - 4100 ± 1400 N
Torque Mxy ± 3000 Nm ± 3400 Nm
Torque Mz ± 450 Nm ± 900 Nm

Requirements on foundation
The table below shows the requirements of the foundation where the manipulator is to be
fitted:

Requirement Value
Min. levelity 0.5 mm
Max. tilt 5°
Min. resonance frequency 30 Hz

Storage conditions
The table below shows the allowed storage conditions for the manipulator:

Parameter Value
Max. ambient temperature, storage +55° C
Max. ambient temperature, storage (less than 24 hrs) +70° C
Min. ambient temperature, storage -25° C
Max. ambient humidity, storage Max. 95% at constant temperature

Operating conditions
The table below shows the allowed operating conditions for the manipulator and controller:

Parameter Value
Max. ambient temperature +45° C
Min. ambient temperature +5° C
Max. ambient humidity Max. 95% at constant temperature

Protection classes
The table below shows the protection class of the main parts of the robot system:

Equipment Protection class


Manipulator IP 67

3HAC 022031-001 Revision: A 43


2 Installation and commissioning
2.2.2. Working range, IRB 2400

2.2.2. Working range, IRB 2400

Working range axis 2-3


This section details the working area of IRB 2400.

IRB 2400L
The working area is the same for both floor and inverted (suspended). Positions at wrist
center.

xx0200000159

Pos.
X Z Angle axis 2
Angle axis 3
0 970 1620 0
0
1 404 2298 0
-60
2 602 745 0
65
3 1577 -246 110
-60
4 400 -403 110
24,5
5 -1611 623 -100
-60
6 -115 1088 -100
65

44 3HAC 022031-001 Revision: A


2 Installation and commissioning
2.2.2. Working range, IRB 2400

2400/10, 16
The working area is the same for both floor and inverted (suspended). Positions at wrist
center.

xx0200000160

Pos.
X Z Angle axis 2
Angle axis 3
0 855 1455 0
0
1 360 2041 0
-60
2 541 693 0
65
3 1351 -118 110
-60
4 400 -302 110
18,3
5 -1350 624 -100
-60
6 -53 1036 -100
65

3HAC 022031-001 Revision: A 45


2 Installation and commissioning
2.3.1. Lifting manipulator with lifting slings

2.3 On-site installation

2.3.1. Lifting manipulator with lifting slings

General
This section details how to lift the manipulator using lifting slings.

Equipment Note
Sling line Type: KDBK 7-8. Length: 2 m. Load at 90°: 380 kg.

Illustration
The following figure shows how to lift the manipulator with lifting slings.

xx0200000164

How to lift the manipulator


1. Release the brakes according to the section, “manualy releasing the brakes”.
2. Adjust the manipulator to lifting position according to the picture.
3. Attach the straps to the special eye bolts on the gear boxes for axes 2 and 3.

46 3HAC 022031-001 Revision: A


2 Installation and commissioning
2.3.2. Manually releasing the brakes

2.3.2. Manually releasing the brakes

General
he section below details how to release the holding brakes of each axis’ motor.
This may be done in one of three ways:
• using the pushbutton when the manipulator is connected to the controller.
• using the pushbutton on the manipulator with an external power supply.
• using an external voltage supply.
DANGER!
When pushing the button all axes are released, the axes become activated very quickly and
the robot may collapse in an unexpected way and cause damage or personal injury.

Using the pushbutton when the manipulator is connected to the controller


This section details how to release the holding brakes using the internal brake release unit.

Step Action Info/Illustration


1. Push the "brake release button" to
release the holding brakes, see
following illustration.

xx0200000168

• A: Pushbutton

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2 Installation and commissioning
2.3.2. Manually releasing the brakes

Using the pushbutton on the manipulator with an external power supply


This section details how to release the holding brakes with the pushbutton using an external
voltage supply.

Step Action Info/Illustration


1. Connect an external power
supply to connector XP1 as
shown in the following
illustration.

xx0200000167

• A: R1.MP
• B: Push button
• C: B8 = +24 V
• D: C10 = 0V
2. Push the "brake release button"
to release the holding brakes,
see the previous illustration.

CAUTION!
Be careful not to interchange the 24V DC and the 0V pins. If they are mixed up, damage can
be caused to a resistor diode and to the system board.

48 3HAC 022031-001 Revision: A


2 Installation and commissioning
2.3.3. Orienting and securing the manipulator

2.3.3. Orienting and securing the manipulator

General
This section details how to orient and secure the manipulator to the foundation in order to
safely run the robot. The requirements for the foundations are shown in the tables and figures
below.

Bolting requirements
When bolting a mounting plate or frame to a concrete floor, follow the general instructions
for expansion-shell bolts. The screw joint must be able to withstand the stress loads difined
in section “Loads on foundation”.
NOTE!
When the robot is to be mounted in a tilted or a suspended position, the guide sleeves must
be used to secure the bolted joint.

Attachment screws
The table below specifies the type of securing screws and washers to be used for securing the
manipulator to the base plate/foundation.

Suitable screws, lightly lubricated: M16 x 50


Quality Quality 8.8
Suitable washer: Thickness: 3 mm
Outer diameter: 30 mm
Inner diameter: 17 mm
Tightening torque: 190 Nm

Hole configuration
The illustration below shows the hole configuration used when securing the manipulator:

xx0200000181

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2 Installation and commissioning
2.3.3. Orienting and securing the manipulator

Cross section, guide sleeve hole


The illustration below shows the cross section of the guide sleeve holes:

xx0200000182

Guide bushings
Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be
remounted without re-adjusting the program.

Equipment Art. no.


Guide sleeves 2151 0024-169

50 3HAC 022031-001 Revision: A


2 Installation and commissioning
2.3.4. Suspended mounting

2.3.4. Suspended mounting

General
The IRB 2400 robot can be mounted in a suspended position, following information is to be
consider when turning the manipulator.

Turning the manipulator


1. Use the special tool for inverted mounting, see following illustration.

xx0200000212

A Lifting beam
B Fork lift
- Inverted mounting tool 3HAC 8961-1

2. Seal the eight holes in the bottom plate with plastic plugs, see following illustration.

3HAC 022031-001 Revision: A 51


2 Installation and commissioning
2.3.4. Suspended mounting

xx0200000215

A Plastic plugs (x8)

52 3HAC 022031-001 Revision: A


2 Installation and commissioning
2.3.5. Loads

2.3.5. Loads

General
Any loads mounted on the manipulator must be defined correctly and carefully (with regard
to the position of center of gravity and inertia factor) in order to avoid jolting movements and
overloading the motors. If this is not done correctly operational stops may result.

References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the
Product Specification. The loads must also be defined in the software as detailed in User’s
Guide (RobotWare 4.0), or Operator’s manual (RobotWare 5.0).

Stop time and braking distances


Manipulator motor brake performance depends on any loads attached. For further
information about brake performance, please contact ABB Robotics.

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2 Installation and commissioning
2.4.1. Introduction

2.4 Restricting the working range

2.4.1. Introduction

General
When installing the robot, make sure that it can move freely within its entire working space.
If there is a risk that it may collide with other objects, its working space should be limited.
The working range of the robot may be limited to eliminate the risk of collisions. The
following axes may be restricted:
• Axis 1, hardware (mechanical stop) and software (signal from adjustable position
switch)
• Axis 2, hardware (mechanical stop) and software (signal from adjustable position
switch)
• Axis 3, hardware (mechanical stop) and software (signal from adjustable position
switch)
This section describes the use of the mechanical stops and/or the position switches.
Notice that adjustments must be made also in the software, references to software manuals
are given in following installation procedures.

54 3HAC 022031-001 Revision: A


2 Installation and commissioning
2.4.2. Mechanically restricting the working range of axis 1

2.4.2. Mechanically restricting the working range of axis 1

General
The axis 1 working range may be restricted mechanically.

Stops
The working range may be restricted by fitting a mechanical stop.

Pos. Description Article number


A Hex socket head cap screw 9ADA 183-65
B Plain washer 9ADA 312-9
C Removable stop axis 1 3HAC 7310-1

If the robot should run into one of these stops during operation, the mechanical stop pin and
the extra moveable mechanical stop arm for axis 1 must be replaced!

xx0200000205

1 Stop axis 1. removable


2 Plain washer
3 Hex socket head cap screw

Mounting extra stops


The section below shows how to mounting an extra mechanical stop.

Step Action Note/Illustration


1. Make a copy of the drilling pattern.
2. Mark out the location of the holes on each stop.
3. Drill the holes through, 10.2 cut threads, M12.
4. Mount the stops without tightening the screws.
5. Turn axis 1 manually and check the working range If necessary correct the
between the stops. angle of impact.

3HAC 022031-001 Revision: A 55


2 Installation and commissioning
2.4.2. Mechanically restricting the working range of axis 1

Drilling pattern for extra stops


Pictures shows the drill pattern to be used when drilling for mechanical stops on axis 1.

xx0200000206

56 3HAC 022031-001 Revision: A


2 Installation and commissioning
2.4.2. Mechanically restricting the working range of axis 1

Drill pattern

xx0200000207

3HAC 022031-001 Revision: A 57


2 Installation and commissioning
2.4.3. Mechanically restricting the working range of axis 2

2.4.3. Mechanically restricting the working range of axis 2

General
The range of rotation for axis 2 can be limited mechanically by fitting extra stops on the lower
arm.

xx0200000208

Number of parts and angles


Number of parts needed for different angles are shown in the table below. Item numbers
refering to the previous illustration.

Working range Qty. item 1 Qty. item 2 Qty. item 3


+110° / -100° - - -
+110° / -70° 1 2 2
+110° / -40° 2 2 4
+80° / -100° 1 2 2
+80° / -70° 2 2 4
+80° / -40° 3 2 6
+50° / -100° 2 2 4
+50° / -70° 3 2 6
+50° / -40° 4 2 8
+20° / -100° 3 2 6
+20° / -70° 4 2 8
+20° / -40° 5 2 10

58 3HAC 022031-001 Revision: A


2 Installation and commissioning
2.4.4. Limiting the working range of axis 3

2.4.4. Limiting the working range of axis 3

General
The working range of axis 3 can be limited by fitting an electrical switch on the gear box axis
3, which senses the position via a cam.

Mounting of eletrical stop


Following illustration shows howe to mount the electrical stop.

xx0200000211

3HAC 022031-001 Revision: A 59


2 Installation and commissioning
2.4.4. Limiting the working range of axis 3

60 3HAC 022031-001 Revision: A


3 Maintenance
3.1. Introduction

3 Maintenance
3.1. Introduction

Structure of this chapter


This chapter details all maintenance activities recommended for the robot and any external
units of the robot.
It is based on the maintenance schedule, located in the beginning of the chapter. The schedule
contains information about required maintenance activities including periodicity and refers to
procedures for the activities.
Each procedure contains all information required to perform the activity, e.g. required tools
and materials.
The procedures are gathered in different sections, divided according to the maintenance
activity.

Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing the procedures. Make sure
to read through the chapter Safety on page 13.

3HAC 022031-001 Revision: A 61


3 Maintenance
3.2.1. Specification of maintenance intervals

3.2 Maintenace schedule

3.2.1. Specification of maintenance intervals

Description
The intervals may be specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the robot:
• Calendar time: specified in months regardless of whether the robot system is run or not
• Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.

62 3HAC 022031-001 Revision: A


3 Maintenance
3.2.2. Maintenance schedule

3.2.2. Maintenance schedule

General
The robot must be maintained regularly to ensure proper function. The maintenance activities
and intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages must be
attended to immediately!
The inspection intervals do not specify the life of each component.

Activities and intervals, standard equipment


The sections referred to in the table can be found in the varius chapters for each maintenance
activity.
The table below specifies the required maintenance activities and intervals:

Maintenance Detailed in
Interval Note
activity section:
Oil change in wrist After first 4,000 h, Change of oil in wrist
unit then every 60 mth.1 unit IRB 2400/10/16 /
12,000 h2 L on page 64
Change of back-up 12-36 mths 3 Measuring the Change the backup
battery for SMB unit capacity of the battery on page 67
battery backup unit to
the SMB
Inspection of all 36 mths Replace if required.
signal cabling in
lower and upper arm
Replacement of 60 mths Replace if bent. Replacement
mechanical stop axis detailed in section .
1
Oil change in 40,000 h Lubricated for life.
gearboxes, axes 1,2, Maintenance free
3 and 4 units.

1. Change the oil for the first time after 4,000 h, then after every 60 month.
2. Valid interval if the robot is working in an environment temperature over 40ºC.
3. The battery is used as a back-up when the robot system is switched off. Therefore, the
life of a lithium battery depends on how frequently the power to the system is switched
off and also if the environment temperature is higher than recommended operating
temperature. The life varies from 12 - 36 mths, depending on current conditions. An
alert is given on the TPU when the battery is nearly discharged and it must then be
replaced within a month.

3HAC 022031-001 Revision: A 63


3 Maintenance
3.3.1. Change of oil in wrist unit IRB 2400/10/16 /L

3.3 Changing activites

3.3.1. Change of oil in wrist unit IRB 2400/10/16 /L

Location of filling cover on wrist unit .


The gearboxes for axes 1, 2, 3 and 4 are lubricated for life with oil which allows for 40 000
hours in operation. Oil in gearboxes 5 and 6 must be changed at the intervals specified on the
maintenance table.
The oil is checked and changed as described in this chapter.

xx0300000069

A Oil plugg
B Oil plugg (air inlet when draining from oil plug A)

Required equipment

Spare
Equipment Art. no. Note
part no.
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures may be These procedures include
required. See references to these references to the tools
procedures in the step-by-step required.
instructions below.

Draining the gearbox (IRB 2400/10, /16)


The procedure below details how to drain the oil from the wrist unit.

64 3HAC 022031-001 Revision: A


3 Maintenance
3.3.1. Change of oil in wrist unit IRB 2400/10/16 /L

WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!

Step Action Note/Illustration


1. Run the upper arm to a horizontal
position and turn axis 4 to the
calibration position.

xx0300000120

2. Remove the oil plugs in the


wristNOTE! loosen the air plug for
better draining.
3. Turn axis 4 through 90° so that the
oil plug on the side of the wrist is
pointing downwards.

xx0300000121

4. Then turn axis 4 another 90°


5. Let the remaining oil run out through
the hole on the tilt housing

3HAC 022031-001 Revision: A 65


3 Maintenance
3.3.1. Change of oil in wrist unit IRB 2400/10/16 /L

New oil is refilled as follows (IRB 2400/10, 16, L)


The procedure below details how to refill the oil in the wrist unit.
NOTE!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may differ from the specified amount, depending on how much
oil has previously been drained from the gearbox.
WARNING!
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!

Step Action Note/Illustration


1. Run the upper arm to a horizontal position and turn
axis 4 to the calibration position.
2. Fill oil in the hole located on the tilt housing (axis 5)
until the oil reaches up to the hole located on the side
of the wrist
3. Note! If the robot is mounted in suspension, the wrist
should be turned 180°
4. Put the oil plugs back in the wrist

66 3HAC 022031-001 Revision: A


3 Maintenance
3.3.2. Change the backup battery

3.3.2. Change the backup battery

Location of SMB back up unit


The figure below shows the location of all the SMB back up unit to be inspected.
The battery to be replaced is located in the base (see Figure). The robot is delivered with a
rechargeable Nickel-Cadmium (Ni-Cd) battery with article number 4944 026-4. The battery
must never be just thrown away; it must always be handled as hazardous waste.

xx0300000067

A SMB backup battery


B SMB backup battery connection cable

Required equipment

Equipment Art. no. Note


Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures may be These procedures include references to
required. See references to these the tools required.
procedures in the step-by-step
instructions below.

Measuring
The procedure below details how to measur the SMB power backup unit

3HAC 022031-001 Revision: A 67


3 Maintenance
3.3.2. Change the backup battery

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Always make sure the cable and hose package is secured with the straps delivered with the
kit. These are specially designed not do damage the cables or hoses.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!

Step Action Note/Illustration


1. Remov the front cover of the robot fot. Described in section
Removal of SMB related
equipment on page 123
2. Set the robot to the MOTORS OFF operating mode.
(This means that it will not have to be coarse-
calibrated after the battery change.)
3. Loosen the battery terminals from the serial
measuring board and cut the clasp that keep the
battery unit in place.
4. Install a new battery with a clasp and connect the
terminals to the serial measuring board.
5. The battery takes 36 hours to recharge; the mains
supply must be switched on during this time and there
must not be any power interrupts.
6. Mount the front cover of the robot fot Described in
sectionReassemble of SMB
related equipment on page
127

Alternative Battery
Alternative Battery As an alternative to the Ni-Cd battery a lithium battery of primary type
can be installed. The lithium battery needs no charging and has for that reason a blocking
diode which prevents charging from the serial measurement board.
The benefit with a lithium 10.8 V battery is the lifetime, which can be up to 5 years in service,
compare with the Ni-Cd battery’s max life time of 3 years in service.
Two lithium batteries exists:
A 3-cell battery art. No. 3HAB 9999-1
A 6-cell battery art. No. 3HAB 9999-2
The life time of the lithium battery depends on how frequently the user switches off the
power.

68 3HAC 022031-001 Revision: A


3 Maintenance
3.3.2. Change the backup battery

The estimated max life time in years for the different lithium batteries and the recommended
exchange interval is shown below

Exchange 3- Exchange 6-
User type:
cell: cell:
Vacation (4 weeks) power off every 5 years every 5 years*
Weekend power off + user type 1 every 2 years every 4 years
Weekend power off + user type 1 and 2 every year every 2 years
* Because of material ageing the maximum life time in
service is 5 years.

Min Max
Ni-Cd 7.0 V 8.7 V
Lithium 7.0 V -

3HAC 022031-001 Revision: A 69


3 Maintenance
3.3.2. Change the backup battery

70 3HAC 022031-001 Revision: A


4 Repair
4.1. Introduction

4 Repair
4.1. Introduction

Structure of this chapter


This chapter details all repair activities recommended for the robot and any external units of
the robot.
It is made up of separate units, each detailing a specific repair activity. Each unit contains all
information required to perform the activity, e.g. spare parts numbers, required special tools
and materials.
The units are gathered in different sections, divided according to the component location on
the robot.

Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in the Product manual, reference information.

Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety on page 13 before commencing any
service work.

3HAC 022031-001 Revision: A 71


4 Repair
4.2.1. Performing a leak-down test

4.2 General procedures

4.2.1. Performing a leak-down test

General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.

Required equipment

Equipment, etc. Art. no. Note


Leakdown tester 3HAC 0207-1
Leak detection spray -

Procedure

Step Action Note/Illustration


1. Finish the refitting procedure of the motor or gear in
question.
2. Remove the topmost oil plug on the gear in question, Art. no. is specified above!
and replace it with the leakdown tester .
Adapters may be required, which are included in the
leakdown tester kit.
3. Apply compressed air, and raise the pressure with the Recommended value: 0.2 -
knob until the correct value is shown on the 0.25 bar (20 - 25 kPa)
manometer.
4. Disconnect the compressed air supply.
5. Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is
be detected. significantly colder or
warmer than the gearbox to
be tested, a slight pressure
increase or decrease
respectively may occur. This
is quite normal.
6. Was any pressure drop evident?
Localize the leak as detailed below.
Remove the leakdown tester, and refit the oil plug.
The test is complete.
7. Spray suspected leak areas with leak detection spray Art. no. is specified above!
.
Bubbles indicate a leak.
8. When the leak has been localized: take the
necessary measures to correct the leak.

72 3HAC 022031-001 Revision: A


4 Repair
4.2.2. Mounting instructions for bearings

4.2.2. Mounting instructions for bearings

General
This section details how to mount and grease different types of bearings on the manipulator.

Equipment

Equipment, etc. Art. no. Note


Grease 3HAB 3537-1 Used to grease the bearings, if not
specified otherwise.

Assembly of all bearings


Follow the instructions below when mounting a bearing on the manipulator.
1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.
2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and
other contamination. Cast components must be free from foundry sand.
3. Bearing rings, inner rings and roller elements must under no circumstances be subjected
to direct impact. Furthermore, the roller elements must not be exposed to any stresses
during the assembly work.

Assembly of tapered bearings


Follow the previous instructions for assembly of all bearings, when mounting a tapered
bearing on the manipulator.
In addition to those instructions, the procedure below must be carried out to enable the roller
elements to adjust to the correct position against the race flange.
1. Tension the bearing gradually until the recommended pre-tension is achieved.
Note! The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the
bearing.

Greasing of bearings
The bearings must be greased after assembly, according to instructions below:
• The bearings must not be completely filled with grease. However, if space is available
beside the bearing fitting, the bearing may be totally filled with grease when mounted,
as excessive grease will be pressed out from the bearing when the robot is started.
• During operation, the bearing should be filled to 70-80% of the available volume.
• Ensure that grease is handled and stored properly, to avoid contamination.
Grease the different types of bearings as detailed below:
• Grooved ball bearings must be filled with grease from both sides.
• Tapered roller bearings and axial needle bearings must be greased in the split
condition.

3HAC 022031-001 Revision: A 73


4 Repair
4.2.3. Mounting instructions for seals

4.2.3. Mounting instructions for seals

General
This sections details how to mount different types of seals to the manipulator.

Equipment

Equipment, etc. Art. no. Note


Grease 3HAB 3537-1 Used to lubricate the seals.

Rotating seals
The procedure below details how to fit rotating seals.
CAUTION!
Please observe the following before commencing any assembly of seals:
• Protect the sealing surfaces during transport and mounting.
• Keep the seal in its original wrappings or protect it well before actual mounting.
• The fitting of seals and gears must be carried out on clean workbenches.
• Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
keyways, etc.

Step Action Note


1. Check the seal to ensure that:
• the seal is of the correct type (provided with cutting
edge).
• there is no damage to the sealing edge (feel with a
fingernail).
2. Inspect the sealing surface before mounting. If scratches or
damage are found, the seal must be replaced, as it may
result in future leakage.
3. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in
early as there is a risk of dirt and foreign particles adhering Equipment on page
to the seal.) 74.
Fill the space between the dust tongue and sealing lip to 2/
3 with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4. Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.

74 3HAC 022031-001 Revision: A


4 Repair
4.2.3. Mounting instructions for seals

Flange seals and static seals


The procedure below details how to fit flange seals and static seals.

Step Action Note


1. Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint
(without sealing compund).
If the flange surfaces are defective, the parts may not be used
beacuse leakage could occur.
2. Clean the surfaces properly and in accordance with ABB
ROBOTICS PRODUCTS recommendations.
3. Distribute the sealing compound evenly over the surface, preferably
with a brush.
4. Tighten the screws evenly when fastening the flange joint.

O-rings
The procedure below details how to fit o-rings.

Step Action Note


1. Ensure that the correct o-ring size is used.
2. Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings
may not be used.
3. Check the o-ring grooves. Defective o-rings
The grooves must be geometrically correct and free from pores may not be used.
and contamination.
4. Lubricate the o-ring with grease.
5. Tighten the screws evenly when assembling.

3HAC 022031-001 Revision: A 75


4 Repair
4.3.1. Removal of cable harness

4.3 Complete robot

4.3.1. Removal of cable harness

Location of Connections in harness


The cable harness is located throughout the manipulator as shown in the figure below.

xx0200000396

A Connector at manipulator base, R1.MP, R1.SMB and R1.C/CS


a1 Electrical connectors rear of the cover plate at the manipulator base , R1.MP1-3,
R1.MP4-6, R1.CS, R1.CP, R1.H1, R2.BU, R2.BU1-3, R2.BU4-6,
a2 Connectors at the serial mesurement board (SMB-unit), R2.SMB1-2 (empty), R2.G
(bat), R2.FB1-3 and R2.FB4-6
B Connectors at motor 2, R3.MP2 and R3.FB2
C Connectors at motor 3, R3.MP3, R3.FB3,R3.LS1 and R3.LS2
D Connectors at motor 1, R3.MP1, R3.FB1
E Connectors at motor 4 (5 kg option), R3.MP4 and R3.FB4
e Connectors at motor 4 (15 kg option), R3.MP4 and R3.FB4
F Connectors at motor 5, R3.MP5 and R3.FB5
G Connectors at motor 6, R3.MP6 and R3.FB6
H Connectors R3.H1 and R3.H2 (5 kg option)
h Connectors R3.H1 and R3.H2 (15 kg option)

76 3HAC 022031-001 Revision: A


4 Repair
4.3.1. Removal of cable harness

Required equipment

Spare
Equipment, etc. Art. no. Note
part no.
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.

Removal, cable harness, axes 1-3


The procedure below details how to remove the cable harness, axes 1-3.

3HAC 022031-001 Revision: A 77


4 Repair
4.3.1. Removal of cable harness

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!

Step Action Note/Illustration


1. In order to facilitate refitting of the cable Axes 2 and 3 may be tilted slightly to
harness, run the manipulator to the improve access.
specified position:
• Axis 1: 0 °
• Axis 2: 0 °
• Axis 3: 0 °
• Axis 4: 0 °
• Axis 5: +90 °
• Axis 6: no significance
2. Remove the rear cover plate (A) on the
manipulator by unscrewing its
attachment screws (B).

xx0200000399

3. Disconnect connectors R1.MP1-3 and


R2.BU1-3.
4. Disconnect all the earth cables on the
R1.M1-3 cable from the back of the
cover.

78 3HAC 022031-001 Revision: A


4 Repair
4.3.1. Removal of cable harness

Step Action Note/Illustration


5. Loosen the nuts (D) holding the SMB-
unit slightly, then remove it carefully from
the bracket.
The cable (A) between the battery (B)
and the SMB-unit (C) may stay
connected, in order to avoid recalibration
of the robot. Be careful not to let the
weight of the SMB-unit strain the cable!
In order to remove the SMB-unit
completely, the connector R2.G must be
disconnected! This causes a necessary
recalibration of the robot! Described in
Removal of SMB related equipment on
page 123.

xx0200000398

6. Disconnect connector R2.FB 1-3 from


the connection R2.SMB1-4 (C) on the
SMB-unit .

xx0200000400

7. Unscrew the four screws securing the This releases the cable harness from the
cable gland. frame.
8. Remove the adapter plate from the
harness by removing its two attachment
screws.

xx0200000404

Note! Different manipulator versions are


fitted with different plate versions. Make
sure the correct one is used to avoid cable
failure.
9. Remove the upper bracket securing the Note! Do not remove or loosen any of the
cables to the arm house by unscrewing cable brackets from the new harness, the
its two attachment screws. angle of the brackets is factory optimized.
10. Remove the back cover of the motors 1- Illustrated in (C) figure below.
3

3HAC 022031-001 Revision: A 79


4 Repair
4.3.1. Removal of cable harness

Step Action Note/Illustration


11. Disconnect all connectors at motor 1, 2
and motor 3,R3.Mp1-3 (A) and R3.FB1-
3 (B)

xx0200000401

12. Remove the 3 screws holding the motor


case on motor 1-3
13. Gently pull the cable harness out.

Removal, cable harness, axes 4-6


The procedure below details how to remove the cable harness, axes 4-6.

xx0200000396

A Connector at manipulator base, R1.MP, R1.SMB and R1.C/CS


a1 Electrical connectors rear of the cover plate at the manipulator base , R1.MP1-3,
R1.MP4-6, R1.CS, R1.CP, R1.H1, R2.BU, R2.BU1-3, R2.BU4-6,
a2 Connectors at the serial mesurement board (SMB-unit), R2.SMB1-2 (empty), R2.G
(bat), R2.FB1-3 and R2.FB4-6
B Connectors at motor 2, R3.MP2 and R3.FB2

80 3HAC 022031-001 Revision: A


4 Repair
4.3.1. Removal of cable harness

C Connectors at motor 3, R3.MP3, R3.FB3,R3.LS1 and R3.LS2


D Connectors at motor 1, R3.MP1, R3.FB1
E Connectors at motor 4 (5 kg option), R3.MP4 and R3.FB4
e Connectors at motor 4 (15 kg option), R3.MP4 and R3.FB4
F Connectors at motor 5, R3.MP5 and R3.FB5
G Connectors at motor 6, R3.MP6 and R3.FB6
H Connectors R3.H1 and R3.H2 (5 kg option)
h Connectors R3.H1 and R3.H2 (15 kg option)

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step Action Note/Illustration


1. In order to facilitate refitting of the cable Axes 2 and 3 may be tilted slightly to
harness, run the manipulator to the improve access.
specified position:
• Axis 1: 0 °
• Axis 2: 0 °
• Axis 3: 0 °
• Axis 4: 0 °
• Axis 5: +90 °
• Axis 6: no significance
2. Remove the rear cover plate (A) on the
manipulator by unscrewing its
attachment screws (B).

xx0200000399

3. Disconnect connectors R1.MP4-6 and


R2.BU4-6.
4. Disconnect all the earth cables on the
R1.M4-6 cable from the back of the
cover.

xx0200000403

3HAC 022031-001 Revision: A 81


4 Repair
4.3.1. Removal of cable harness

Step Action Note/Illustration


5. Loosen the nuts (D) holding the SMB-
unit slightly, then remove it carefully from
the bracket.
The cable (A) between the battery (B)
and the SMB-unit (C) may stay
connected, in order to avoid
recalibration of the robot. Be careful not
to let the weight of the SMB-unit strain
the cable!
In order to remove the SMB-unit
completely, the connector R2.G must be
disconnected! This causes a necessary
recalibration of the robot! Described
inReassemble of SMB related
equipment on page 127.
xx0200000398

6. Disconnect connector R2.FB 4-6 from


the connection R2.SMB4-6 (B) on the
SMB-unit .

xx0200000400

7. Unscrew the four screws securing the This releases the cable harness from the
cable gland. frame.
8. Remove the adapter plate from the
harness by removing its two attachment
screws (A).

xx0200000404

Note! Different manipulator versions are


fitted with different plate versions. Make
sure the correct one is used to avoid cable
failure.

82 3HAC 022031-001 Revision: A


4 Repair
4.3.1. Removal of cable harness

Step Action Note/Illustration


9. Remove the upper bracket securing the
cables to the arm house by unscrewing
its two attachment screws (C).
Cut the strip clamp (B)

xx0200000405

10. Remove the back cover of the motors 4-


6, fitted with torx screw.
11. Disconnect all connectors at motor 4, 5
and motor 6,R3.Mp4-6 and R3.FB4-6
A- R3.mp5
B- R3.mp6
C- R3.mp4
D- R3.fb5
E- R3.fb6
F- R3.fb4

xx0200000406

12. Remove all screws holding the motor


case on motor 4-6
13. Gently pull the cable harness out.

3HAC 022031-001 Revision: A 83


4 Repair
4.3.2. Refitting of cable harness

4.3.2. Refitting of cable harness

Location of cable harness


The cable harness is located throughout the manipulator as shown in the figure below.

Location of Connections in harness

xx0200000396

A Connector at manipulator base, R1.MP, R1.SMB and R1.C/CS


a1 Electrical connectors rear of the cover plate at the manipulator base , R1.MP1-3,
R1.MP4-6, R1.CS, R1.CP, R1.H1, R2.BU, R2.BU1-3, R2.BU4-6,
a2 Connectors at the serial mesurement board (SMB-unit), R2.SMB1-2 (empty), R2.G
(bat), R2.FB1-3 and R2.FB4-6
B Connectors at motor 2, R3.MP2 and R3.FB2
C Connectors at motor 3, R3.MP3, R3.FB3,R3.LS1 and R3.LS2
D Connectors at motor 1, R3.MP1, R3.FB1
E Connectors at motor 4 (5 kg option), R3.MP4 and R3.FB4
e Connectors at motor 4 (15 kg option), R3.MP4 and R3.FB4
F Connectors at motor 5, R3.MP5 and R3.FB5
G Connectors at motor 6, R3.MP6 and R3.FB6
H Connectors R3.H1 and R3.H2 (5 kg option)
h Connectors R3.H1 and R3.H2 (15 kg option)

84 3HAC 022031-001 Revision: A


4 Repair
4.3.2. Refitting of cable harness

Spare part
Equipment, etc. Art. no. Note
no.
Cable unit, axes 1-3 3HAC 4791-1
Cable unit, axes 4-6 3HAC 8865-1
Cable unit, axes 4-6 Opt 3HAC 8520-1 Option 043
043
Motor gasket for motor 1-3 3HAC 4419-1
Motor gasket for motor 4-6 3HAB 4429-1
Sealing 3HAB 5922-1
Loctite 574 1234 0011-116 Flange sealing
Cable straps 2166 2055-3 L=208mm
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.

Refitting, cable harness, axes 1-3


The procedure below details how to refit the cable harness, axes 1-3.

3HAC 022031-001 Revision: A 85


4 Repair
4.3.2. Refitting of cable harness

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!

Step Action Note/Illustration


1. In order to facilitate refitting of the cable Axes 2 and 3 may be tilted slightly to
harness, run the manipulator to the improve access.
specified position:
• Axis 1: 0 °
• Axis 2: 0 °
• Axis 3: 0 °
• Axis 4: 0 °
• Axis 5: +90 °
• Axis 6: no significance
2. Gently pull the down the cable harness
through the center hole of axis 1.
3. Mount the motor case on motor 1-3 using Note! Always mount a new gasket art
the 3 screws no. 3HAC 4419-1
4. Reconnect all connectors at motor 1, 2
and 3. R3.Mp 1-3 (A) and R3.FB 1-3 (B)

xx0200000401

5. Mount the back cover of the motors 1-3 Use the 5 Torx screw fitted in the holes
(C) in figure above.
6. Mount the upper bracket securing the
cables to the arm house, using the two
attachment screws.

86 3HAC 022031-001 Revision: A


4 Repair
4.3.2. Refitting of cable harness

Step Action Note/Illustration


7. Mount the adapter plate to the harness by
using its two attachment screws (A).

xx0200000404

Note! Different manipulator versions are


fitted with different plate versions. Make
sure the correct one is used to avoid
cable failure.
8. Mount all the screws securing the cable
gland.
This attaches the cable harness to the
frame.
Cables
1. A- Power
2. B- Power
3. C- Power
4. D- Customer
5. E- Signal
6. F- Signal

xx0200000402

Note! Make sure that each cable is


mounted in the same position as the old
ones, otherwise the conduit entry will not
be watertight, use 6 cable straps no.
2166 2055-3
Note! Always use a new sealing no.
3HAB 5922-1 and combine it with a
flange sealing type Loctite 574 no. 1234
0011-116 for best result.

3HAC 022031-001 Revision: A 87


4 Repair
4.3.2. Refitting of cable harness

Step Action Note/Illustration


9. Connect connectors R2.FB 1-3 to the
connection R2.SMB1-4 (C) on the SMB-
unit .

xx0200000400

10. Mount the SMB-unit to the bracket with


the nuts (D), be careful not to let the
weight of the SMB-unit strain the cable!
(A). Described in Reassemble of SMB
related equipment on page 127

xx0200000398

Note! The cable (A) between the battery


(B) and the SMB-unit (C) may stay
connected, in order to avoid
recalibration of the robot.
11. Mount all the earth cables on the R1.M1-
3 cable to the back of the cover.

xx0200000403

12. Connect connectors R1.MP1-3 and


R2.BU1-3.
13. Mount the rear cover plate (A) on the
manipulator with its attachment screws
(B).

xx0200000399

88 3HAC 022031-001 Revision: A


4 Repair
4.3.2. Refitting of cable harness

Refitting, cable harness, axes 4-6


The procedure below details how to refit the cable harness, axes 4-6.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!

Step Action Note/Illustration


1. In order to facilitate refitting of the Axes 2 and 3 may be tilted slightly to improve
cable harness, run the manipulator to access.
the specified position:
• Axis 1: 0 °
• Axis 2: 0 °
• Axis 3: 0 °
• Axis 4: 0 °
• Axis 5: +90 °
• Axis 6: no significance
2. Gently pull the down the cable
harness through the center of lower
robot arm and through the hole of
axis 1.
3. Mount the motor case on motor 4-6 Note! Always mount a new gasket art no.
using the 9 torx screws 3HAB 4429-1

3HAC 022031-001 Revision: A 89


4 Repair
4.3.2. Refitting of cable harness

Step Action Note/Illustration


4. Reconnect all connectors at motor 4,
5 and 6. R3.Mp 4-6 (A) and R3.FB 1-
3 (B)
A- R3.mp5
B- R3.mp6
C- R3.mp4
D- R3.fb5
E- R3.fb6
F- R3.fb4

xx0200000406

xx0300000063

xx0300000062

90 3HAC 022031-001 Revision: A


4 Repair
4.3.2. Refitting of cable harness

Step Action Note/Illustration


5. Mount the back cover of the motors
4-6
6. Mount the upper bracket securing
the cables to the arm house, using
the two attachment screws.
7. Mount the adapter plate to the
harness by using its two attachment
screws (A).

xx0200000404

Note! Different manipulator versions are fitted


with different plate versions. Make sure the
correct one is used to avoid cable failure.
8. Mount all the screws securing the
cable gland.
This attaches the cable harness to
the frame.
Cables
1. A- Power
2. B- Power
3. C- Power
4. D- Customer
5. E- Signal
6. F- Signal

xx0200000402

Note! Make sure that each cable is mounted


at the same position as the old ones,
otherwise the conduit entry will not be
watertight.
Note! Always use a new sealing no. 3HAB
5922-1 and combine it with a flange sealing
type Loctite 574 no. 1234 0011-116 for best
result.

3HAC 022031-001 Revision: A 91


4 Repair
4.3.2. Refitting of cable harness

Step Action Note/Illustration


9. Connect connectors R2.FB 4-6 to the
connection R2.SMB4-6 (B) on the
SMB-unit .

xx0200000400

10. Mount the SMB-unit to the bracket


with the nuts (D), be careful not to let
the weight of the SMB-unit strain the
battery cable! (A). Described
inReassemble of SMB related
equipment on page 127

xx0200000398

Note! The cable (A) between the battery (B)


and the SMB-unit (C) may stay connected, in
order to avoid recalibration of the robot.
11. Mount all the earth cables on the
R1.M4-6 cable to the back of the
cover.

xx0200000403

12. Connect connectors R1.MP4-6 and


R2.BU4-6.
13. Mount the rear cover plate (A) on the
manipulator with its attachment
screws (B).

xx0200000399

92 3HAC 022031-001 Revision: A


4 Repair
4.4.1. Removal of wrist IRB 2400/10/16.

4.4 Upper arm

4.4.1. Removal of wrist IRB 2400/10/16.

Location of wrist
The wrist is defined as the manipulators axis 5 and 6, This is shown in pos (A) in the figure
below.

xx0200000409

A Wrist
B Upper arm
C Lower arm
D Frame
E Fot

3HAC 022031-001 Revision: A 93


4 Repair
4.4.1. Removal of wrist IRB 2400/10/16.

Required equipment

Spare part Art.


Equipment, etc. Note
no. no.
Lifting device, manipulator
Special toolkit
Standard toolkit The contents are defined in
section Standard toolkit in
the Product manual,
reference information!
Other tools and procedures may be These procedures include
required. See references to these references to the tools
procedures in the step-by-step required.
instructions below.

Location
The procedure below details how to remove the wrist from the robot upper arm.

xx0300000104

A Screws
B Oil-plug
C Wrist

The wrist, which includes axes 5 and 6, is a complete unit comprising drive units and
gearboxes. It is a replacement unit of complex design and should not normally be serviced
on-site. Instead it should be sent to ABB for service etc.
ABB recommends its customers to carry out only the following servicing and repair work on
the wrist.

94 3HAC 022031-001 Revision: A


4 Repair
4.4.1. Removal of wrist IRB 2400/10/16.

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!

Step Action Note/Illustration


1. Remove the oil plug on the wrist and drain it from all Shown in figure in section
the oil. Location of wrist on page 93
2. Undo screws and remove the wrist. Shown in figure in section
Location of wrist on page 93

3HAC 022031-001 Revision: A 95


4 Repair
4.4.2. Refitting of wrist IRB 2400/10/16

4.4.2. Refitting of wrist IRB 2400/10/16

Location of wrist
The wrist is defined as the manipulators axis 5 and 6. This is shown in pos (A) in the figure
below.

xx0200000409

A Wrist
B Upper arm
C Lower arm
D Frame
E Foot

Required equipment

Spare part Art.


Equipment, etc. Note
no. no.
Lifting device, manipulator
Special toolkit
Grease 3HAB 3537-1 Shell Alvania WR2

96 3HAC 022031-001 Revision: A


4 Repair
4.4.2. Refitting of wrist IRB 2400/10/16

Spare part Art.


Equipment, etc. Note
no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.

Reassemble the new wrist


The wrist, which includes axes 5 and 6, is a complete unit comprising drive units and
gearboxes. It is a replacement unit of complex design and should not normally be serviced
on-site. Instead it should be sent to ABB for service.
The procedure below details how to refitt the wrist to the robot upper arm.

xx0300000104

A Screws
B Oil-plug
C Wrist

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!

3HAC 022031-001 Revision: A 97


4 Repair
4.4.2. Refitting of wrist IRB 2400/10/16

Step Action Note/Illustration


1. Clean the surface of the tubular shaft.
2. Grease the O-ring with grease Shell Alvania Shown in Reassemble the new
WR2, ABB’s art. No, 3HAB 3537-1, to be sure wrist on page 97
that the O-ring between the upper arm tubular
and the wrist do not get displaced, and mount it
in its position on the upper arm tubular.
3. Mount two M8 guide pins (A) (length = 70 mm)
diagonally on the wrist. Carefully push the wrist
against the tubular. When the gears are meeting
each other, they may need to be rotated to mesh
properly.

xx0200000424

4. Fix the wrist with two screws and two washers.


Dismantle the M8 guide pins. Mount the other
two screws and washers.
5. Release the brakes on axes 5 and 6 (one at the Manually releasing the brakes on
time) and mount tool 3HAB 7887-1 at the rear of page 47
the motor.
6. Push the wrist, as shown in Figure, to locate the
smallest play in the same way as for adjustment
of play when changing motors for axes 5 and 6,
see the section Refitting of motor, axis 4-6 on
page 162

xx0200000425

A- Gears on drive shaft unit, axis


5-6
B- Gears on the wrist
7. Tighten screws (A) with washer to a torque of 17
Nm
8. Check the play by moving axes 5 and 6 by hand
9. Fill with oil. See the sectionChange of oil in
wrist unit IRB 2400/10/16 /L on
page 64
10. Calibrate the robot. Calibration is detailed in separate
calibration manuals.
Art. no. for the manuals are
specified in section Document
references in the Product
manual, reference information.

98 3HAC 022031-001 Revision: A


4 Repair
4.4.3. Removal of wrist IRB 2400L

4.4.3. Removal of wrist IRB 2400L

Location of wrist
The wrist is defined as the manipulators axis 5 and 6, This is shown in pos (A) in the figure
below.

x0300000409

A Wrist
B Upper arm
C Lower arm
D Frame
E Foot

Required equipment

Spare
Equipment, etc. Art. no. Note
part no.
Lifting device, manipulator
Special toolkit

3HAC 022031-001 Revision: A 99


4 Repair
4.4.3. Removal of wrist IRB 2400L

Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures may These procedures include
be required. See references to references to the tools
these procedures in the step-by- required.
step instructions below.

Location
The procedure below details how to remove the wrist from the robot upper arm.
The wrist, which includes axes 5 and 6, is a complete unit comprising drive units and
gearboxes. It is a replacement unit of complex design and should not normally be serviced
on-site. Instead it should be sent to ABB for service etc.
ABB recommends its customers to carry out only the following servicing and repair work on
the wrist.
WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

100 3HAC 022031-001 Revision: A


4 Repair
4.4.3. Removal of wrist IRB 2400L

Step Action Info/Illustration


1. Remove the oil plug on the wrist and
drain it from all the oil.

x0300000104

• A : Screw
• B : Oil plug (air inlet)
• Wrist unit
2. Undo screws and remove the wrist

3HAC 022031-001 Revision: A 101


4 Repair
4.4.4. Refitting of wrist IRB 2400L.

4.4.4. Refitting of wrist IRB 2400L.

Location of wrist
The wrist is defined as the manipulators axis 5 and 6, This is shown in pos (A) in the figure
below.

x0200000409

A Wrist
B Upper arm
C Lower arm
D Frame
E Foot

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.

102 3HAC 022031-001 Revision: A


4 Repair
4.4.4. Refitting of wrist IRB 2400L.

Spare part
Equipment, etc. Art. no. Note
no.
Grease
Lifting device, manipulator

Location

Step Action Info/Illustration


1. Clean the surface of the tubular shaft
2. Apply Loctite 574 all around.
3. Mount the wrist, tighten screws to a torque of
8.3 Nm 10±%
4. Screw the clamping sleeves together using
screws to a torque of 5.7 Nm
5. Replace the plugs
6. Mount the cover at the motor side of axis 5-6.
7. Calibrate the robot! Calibration is detailed in separate
calibration manuals.
Art. no. for the manuals are
specified in section Document
references in the Product manual,
reference information.

3HAC 022031-001 Revision: A 103


4 Repair
4.4.5. Removal of complete upper arm

4.4.5. Removal of complete upper arm

Location
The upper arm is located on top of the manipulator as shown in (A) and (B) the figure below.
The complete upper arm includes the wrist unit.

xx0200000409

A Wrist axis 5-6


B Upper arm axis 4-3
C Lower arm axis 2
D Frame axis 1
E Robot foot

Required equipment

Spare part
Equipment Art. no. Note/Illustration
no.
Lifting device, upper arm
Special tool 3HAB 9009-1
Lifting tool (chain) To be used together with lifting eye,
M12 and lifting device, upper arm.

104 3HAC 022031-001 Revision: A


4 Repair
4.4.5. Removal of complete upper arm

Spare part
Equipment Art. no. Note/Illustration
no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.

Tie Rod attachment

xx0200000436

A Cover
B KM nuts
C Screw

Removal
The procedure below details how to remove the complete upper arm.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!

3HAC 022031-001 Revision: A 105


4 Repair
4.4.5. Removal of complete upper arm

Step Action Note/Illustration


1. Dismount the tie rod as described
in chapter Removal of the tie rod on
page 117
2. Loosen the connectors of the Detailed in Removal of motor, axis 4-6;IRB
motors of axes 4, 5 and 6 2400L on page 159
3. Disconnect the connection box
from the motors.
4. Remove the covers (Left + Right) Detailed in Tie Rod attachment on page 105
5. Undo the KM nuts (Left + Right). Detailed in Tie Rod attachment on page 105
Use sleeve 6369 901-480
6. Remove screws (Left + Right) Detailed in Tie Rod attachment on page 105
7. Mount the lifting device to the
upper arm, and lift enough for the
strap to stretch without lifting the
robot.

xx0200000435

Lifting without lifting tool!


8. Pull out the shaft. Use tool 3HAB
9009-1. Mark the shafts (left, right).

106 3HAC 022031-001 Revision: A


4 Repair
4.4.6. Reassemble of complete upper arm

4.4.6. Reassemble of complete upper arm

Location
The upper arm is located on top of the manipulator as shown in (A) and (B) the figure below.
The complete upper arm includes the wrist unit.

xx0200000409

A Wrist axis 5-6


B Upper arm axis 4-3
C Lower arm axis 2
D Frame axis 1
E Robot foot

Required equipment

Spare part Art.


Equipment Note/Illustration
no. no.
Lifting device, upper arm
Special tool 3HAB 9009-1
Lifting tool Lifting strap

3HAC 022031-001 Revision: A 107


4 Repair
4.4.6. Reassemble of complete upper arm

Spare part Art.


Equipment Note/Illustration
no. no.
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these procedures
in the step-by-step instructions
below.

Tie Rod attachment

xx0200000436

A Cover
B KM nuts
C Screw

Reassemble
The procedure below details how to reinstall the complete upper arm.

108 3HAC 022031-001 Revision: A


4 Repair
4.4.6. Reassemble of complete upper arm

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
WARNING!
Ensure that
• - the area around the manipulator is clear as the machine can swing round as it leaves
the pallet!
• - the trolley has free movement while lifting. If the trolley gets stuck, the manipulator
is likely to fall off and can cause personal injury and damage to the manipulator!

Step Action Note/Illustration


1. Mount sealings in the upper arm
2. Mount the inner ring of the bearings on shafts. Use tool No. 3HAB 6464-1.
3. Raise the upper arm into the assembly position.
4. Install shaft spindles (both sides).
5. Insert screws and tighten. 90 Nm
6. The following procedure must be performed within 10 Illustrated in section Tie Rod
minutes, before the Loctite starts to harden. attachment on page 108
• Apply Loctite 243 on the KM-nuts (B)
• Tighten the KM-nut on the left side first (robot
seen from behind) so that the bearing comes
against the collar.
• Unscrew the KM-nut and then tighten with a
torque of 35 Nm
• Tighten the KM-nut on the right side, move the
upper arm up and down at the same time, until
there is no play
• Unscrew the nut again.
• Tighten the KM-nut with a torque of 35 Nm
• Mount the covers (A)
• Push in a strap from the other under the
sealing, so that the air can go out
7. Mount the sync. plate for axis 3.
8. Reconnect the connection boxes and the cabling.
9. Calibrate the robot as specified in this chapter,
Calibration in the installation manual

3HAC 022031-001 Revision: A 109


4 Repair
4.5.1. Removal of complete lower arm

4.5 Lower arm

4.5.1. Removal of complete lower arm

Location of lower arm


The lower arm is located as shown (C) in the figure below.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000409

A Wrist
B Upper arm
C Lower arm
D Frame
E Robot foot

110 3HAC 022031-001 Revision: A


4 Repair
4.5.1. Removal of complete lower arm

Required equipment

Equipment, etc. Spare part no. Art. no. Note


Hoisting equipment
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and These procedures include references to
procedures may be the tools required.
required. See
references to these
procedures in the
step-by-step
instructions below.

Lifting off the lower arm

xx0200000439

Removal of complete lower arm


The procedure below details how to remove the complete lower arm.

3HAC 022031-001 Revision: A 111


4 Repair
4.5.1. Removal of complete lower arm

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Some parts are HOT after running the robot, e.g. motors and lights! Burns may result
from touching them!
• Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
• When replacing motors/reducers, make sure that those parts of the robot which could
move unexpectedly are mechanically blocked as specified in the individual
procedures.
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.

Step Action Note/Illustration


1. Remove the upper arm.

xx0200000435

Detailed in Removal of complete upper


arm on page 104.
2. Attach the crane to the lower arm Shown in the figure in section Lifting off the
lower arm on page 111
3. Remove the tie rod. Detailed in Removal of the tie rod on page
117.
4. Remove the parallel arm Detailed in Removal of the parallel arm on
page 135
5. Disconnect and remove the cables from Detailed in Removal of cable harness on
inside the lower arm. page 76.
Release any cable attachments.

112 3HAC 022031-001 Revision: A


4 Repair
4.5.1. Removal of complete lower arm

Step Action Note/Illustration


6. Loosen all screws (A)

xx0200000440

7. Take off the lower arm Shown in the figure in section Lifting off the
lower arm on page 111

3HAC 022031-001 Revision: A 113


4 Repair
4.5.2. Refitting of complete lower arm

4.5.2. Refitting of complete lower arm

Location of lower arm


The lower arm (C) is located as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000409

A Wrist
B Upper arm
C Lower arm
D Frame
E Robot foot

114 3HAC 022031-001 Revision: A


4 Repair
4.5.2. Refitting of complete lower arm

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Bearing Grease 3HAB 3537-1 For lubricating shaft hole
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.

Reassemble of lower arm

xx0200000441

Refitting, lower arm


The procedure below details how to refit the complete lower arm.

3HAC 022031-001 Revision: A 115


4 Repair
4.5.2. Refitting of complete lower arm

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
WARNING!
Ensure that
• - the area around the manipulator is clear as the machine can swing round as it leaves
the pallet!
• - the trolley has free movement while lifting. If the trolley gets stuck, the manipulator
is likely to fall off and can cause personal injury and damage to the manipulator!

Step Action Note/Illustration


1. Transfer the damping element and Only if the arm is replaced with a new.
calibration marking to the new lower
arm.
2. Lift the lower arm into position. Shown in illustration Reassemble of lower arm
on page 115
3. Fix the lower arm to gearbox 2 using 68 Nm
screws and tighten.
4. Assemble the parallel arm Detailed in chapterReassemble of the parallel
arm on page 137
5. Fix the parallel arm to gearbox 3 68 Nm
using screws and tighten.
6. Replace the upper arm Detailed in chapterReassemble of complete
upper arm on page 107
7. Replace the cabling Described in chapter Refitting of cable harness
on page 84
8. Recalibrate the robot! Calibration is detailed in separate calibration
manuals.
Art. no. for the manuals are specified in section
Document references in the Product manual,
reference information.

116 3HAC 022031-001 Revision: A


4 Repair
4.5.3. Removal of the tie rod

4.5.3. Removal of the tie rod

Location of tie rod


The tie rod is located as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000442

A Tie rod
B Parallel arm

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.

3HAC 022031-001 Revision: A 117


4 Repair
4.5.3. Removal of the tie rod

Tie rod

xx0200000443

A Bearing Sealing
B Back up ring
C Screw, hex. socket head cap
D Locking Washer
E Bearing
Upper connection IRB 2400 5 kg
F Bearing Sealing
G Bearing
H Bearing Sealing
I Screw

Removal of tie rod


The procedure below details how to remove the tie rod.

118 3HAC 022031-001 Revision: A


4 Repair
4.5.3. Removal of the tie rod

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!

Step Action Note/Illustration


1. Remove screw (A) upper. Shown in Illustration Tie rod
on page 118
2. Remove screw (A) lower. Shown in Illustration Tie rod
on page 118
3. Remove Locking Washer (B) Shown in Illustration Tie rod
on page 118
4. Insert a screw in the center, to be used as support.
5. Use a crane to secure the upper arm. Shown in figure in section
Location of tie rod on page
117
6. Use a puller to pull out the tie rod
7. Change the bearings (D) and seals Shown in Illustration Tie rod
on page 118

3HAC 022031-001 Revision: A 119


4 Repair
4.5.4. Reassemble of the tie rod

4.5.4. Reassemble of the tie rod

Location of tie rod


The tie rod is located as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000444

A Tie rod
B Parallel arm

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Loctite 243
Grease
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.

120 3HAC 022031-001 Revision: A


4 Repair
4.5.4. Reassemble of the tie rod

Tie rod

xx0200000443

A Bearing Sealing
B Back up ring
C Screw, hex. socket head cap
D Locking Washer
E Bearing
Upper connection IRB 2400 5 kg
F Bearing Sealing
G Bearing
H Bearing Sealing
I Screw

Reassemble
The procedure below details how to reassemble the tie rod.
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.

3HAC 022031-001 Revision: A 121


4 Repair
4.5.4. Reassemble of the tie rod

Step Action Note/Illustration


1. Be sure to secure the upper arm. Use a crane!
Shown in figure section Location of tie
rod on page 120
2. Fit the new bearings in the tie rod (D). Shown in section Tie rod on page 121
Use special tool 3HAB 6324-1.
3. Fit a new shaft sealing (E). Shown in section Tie rod on page 121
Use special tool 3HAB 6324-1.
4. Refit the tie rod.. Use special tool 3HAB 6331-1.
5. Refit the back up ring Shown in section Tie rod on page 121
6. Refit the Locking Washer Shown in section Tie rod on page 121
7. Refit all screws. Shown in section Tie rod on page 121
Secure with Loctite 243

122 3HAC 022031-001 Revision: A


4 Repair
4.6.1. Removal of SMB related equipment

4.6 Frame and base

4.6.1. Removal of SMB related equipment

Location of SMB board


The SMB related equipment (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.
Note that the manipulator is shown with the SMB cover already removed!

xx0200000451

A Cable to back up battery


B Back up battery
C Serial Measurement Board
D Lock Nuts

3HAC 022031-001 Revision: A 123


4 Repair
4.6.1. Removal of SMB related equipment

Required equipment

Spare
Equipment, etc. Art. no. Note
part. no.
Gasket 3HAB 5537-1
SMB- unit 3HAB 8413-01
Battery unit 4944 026-4
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Circuit Diagram See chapter Circuit diagram in
the Product manual, reference
information.
Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
procedures in the step-by-
step instructions below.

Cover robot foot

xx0200000399

A Cover plate
B Screw

Removal, cover on robot foot


The procedure below details how to remove the cover on the robot foot

124 3HAC 022031-001 Revision: A


4 Repair
4.6.1. Removal of SMB related equipment

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step Action Note/Illustration


1. Remove the Screws to the cover Shown in the illustration
Cover robot foot on page
124
2. Remove the cover gasket art. no. 3HAB 5537-1 NOTE! Always change every
removed gasket .

Removal, battery
The procedure below details how to remove the SMB battery.

Step Action Note/Illustration


1. Remove the SMB battery cover by unscrewing its Shown in figure in section
attachment screws . Location of SMB board on
page 123
2. Disconnect the battery from the cable, battery/SMB
board .
3. Remove the SMB battery.

3HAC 022031-001 Revision: A 125


4 Repair
4.6.1. Removal of SMB related equipment

SMB unit

xx0200000452

A R2.SMB1-2 (External axis)


B R2.SMB1-3
C R2.SMB4-6
D Back up battery (R2.G)
E R2.SMB (Motor Brake)

Removal, SMB unit


The procedure below details how to remove the SMB unit.
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.

Step Action Note/Illustration


1. Remove the SMB battery. Detailed above in Removal,
battery on page 125.
2. Remove the SMB cover by unscrewing its
attachment screws.
Pull the battery cable through the hole in the SMB
cover.
3. Remove the two locknuts and washers from the pins Shown in illustration SMB
securing the board. unit on page 126
4. Gently disconnect the connectors from the SMB unit Connectors R1.SMB1-3,
when pulling the board out. R1.SMB4-6 and R2.SMB
5. Also disconnect the battery cable from the SMB unit.

126 3HAC 022031-001 Revision: A


4 Repair
4.6.2. Reassemble of SMB related equipment

4.6.2. Reassemble of SMB related equipment

Location of SMB board


The SMB related equipment (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.
Note that the manipulator is shown with the SMB cover already removed!

xx0200000451

A Cable to back up battery


B Back up battery
C Serial Measurement Board
D Lock Nuts

3HAC 022031-001 Revision: A 127


4 Repair
4.6.2. Reassemble of SMB related equipment

Required equipment

Spare
Equipment, etc. Art. no. Note
part. no.
Gasket 3HAB 5537-1
SMB- unit 3HAB 8413-01
Battery unit 4944 026-4
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.

SMB unit

xx0200000452

A R1.SMB1-2
B R1.SMB1-3
C R1.SMB4-6
D R2.G
E R2:SMB

128 3HAC 022031-001 Revision: A


4 Repair
4.6.2. Reassemble of SMB related equipment

Reassemble, SMB unit


The procedure below details how to reassemble the SMB unit.

Step Action Note/Illustration


1. Gently connect the connectors to the SMB Connectors R1.SMB1-3 (B), R1.SMB4-6
unit when pushing the board in. (C) and R2.SMB (E) Shown in illustration
in section SMB unit on page 128
2. Reassemble the SMB cover using the Shown in figure in section Location of
attachment lock nuts. SMB board on page 127
Pull the battery cable through the hole in
the SMB cover.
3. Reassemble the two locknuts and washers Shown in figure in section Location of
to the pins securing the board. SMB board on page 127

Reassemble of, battery


The procedure below details how to reassemble the SMB battery.

Step Action Note/Illustration


1. Reassemble the SMB battery .
2. Connect the battery to the cable, battery/SMB board Pos (D) R2.G Shown in
. illustration in section SMB unit
on page 128
3. Reassemble the SMB battery cover using its Shown in figure in section
attachment screws. Location of SMB board on page
127

Cover robot foot

xx0200000399

A Cover
B Screws

Reassemble of, cover on robot foot


The procedure below details how to reassemble the cover on the robot foot

3HAC 022031-001 Revision: A 129


4 Repair
4.6.2. Reassemble of SMB related equipment

Step Action Note/Illustration


1. Reassemble the cover gasket . NOTE! Always change every
removed gasket .
Art.no. 3HAB 5537-1
2. Reassemble the Screws holding the cover Shown in the illustration
Cover robot foot

130 3HAC 022031-001 Revision: A


4 Repair
4.6.3. Removal of brake release unit

4.6.3. Removal of brake release unit

Location and description of brake release unit


The push-button unit is located on the flange plate on the base and is used to quickly and
safely release the axis brakes manually, when doing various types of work on and around the
robot. It is also possible to move the arms of the robot manually, when this is necessary.
The push-button unit (A) is equipped with six buttons for controlling the axis brakes. The
buttons are numbered with the axes numbers. The unit is located underneath a rubber cover
in the cover. The brakes are of electromechanical type and are released when voltage is
applied. To release the brake on a particular axis, push the appropriate button and keep it
depressed. The brake will function again as soon as the button is released.

xx0200000459

A Brake release

Required equipment

Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.

Removal of brake release unit


The procedure below details how to remove the brake release circuit, located at the rear of the
base.

3HAC 022031-001 Revision: A 131


4 Repair
4.6.3. Removal of brake release unit

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Some parts are HOT after running the robot, e.g. motors and lights! Burns may result
from touching them!
• Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
• When replacing motors/reducers, make sure that those parts of the robot which could
move unexpectedly are mechanically blocked as specified in the individual
procedures.
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.
CAUTION!
If the manipulator normally works in an inverted position, it must be removed from this
position and placed on the floor before the work detailed in this instruction may be carried
out !

Step Action Note/Illustration


1. Remove the cover at the rear of the base.
2. Unscrew the six attachment screws to the brake Shown in section Location
release circuit on the outside of the base. and description of brake
release unit on page 131
3. Disconnect the cable from the brake release circuit
and remove the circuit from the base.

132 3HAC 022031-001 Revision: A


4 Repair
4.6.4. Reassemble of brake release unit

4.6.4. Reassemble of brake release unit

Location and description of brake release unit


The push-button unit is located on the flange plate on the base and is used to quickly and
safely release the axis brakes manually, when doing various types of work on and around the
robot. It is then also possible to move the arms of the robot manually, when this is necessary.
The push-button unit (A) is equipped with six buttons for controlling the axis brakes. The
buttons are numbered with the axes numbers. The unit is located underneath a rubber cover
in the cover. The brakes are of electromechanical type and are released when voltage is
applied. To release the brake on a particular axis, push the appropriate button and keep it
depressed. The brake will function again as soon as the button is released.

xx0200000463

A Brake release unit, axis 1-6

Required equipment

Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.

Removal of brake release unit


The procedure below details how to reassemble the brake release circuit, located at the rear
of the base.

3HAC 022031-001 Revision: A 133


4 Repair
4.6.4. Reassemble of brake release unit

NOTE!
The robot must not be in the STANDBY MODE! This applies for all types of cabling work.

NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Some parts are HOT after running the robot, e.g. motors and lights! Burns may result
from touching them!
• Turn off all electrical power, hydraulic and pneumatic pressure supplies to the robot!
• When replacing motors/reducers, make sure that those parts of the robot which could
move unexpectedly are mechanically blocked as specified in the individual
procedures.

Step Action Note/Illustration


1. Reconnect the cable to the brake release circuit and Shown in section Required
reassemble the circuit to the base. equipment on page 133
2. Use the six attachment screws to the brake release Shown in section Required
circuit on the outside of the base. equipment on page 133
3. Reassemble the cover at the rear of the base.

134 3HAC 022031-001 Revision: A


4 Repair
4.6.5. Removal of the parallel arm

4.6.5. Removal of the parallel arm

Location of parallel arm


The parallel arm is located as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000444

A Tie rod
B Parallel arm

Required equipment

Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Special toolkit
Other tools and procedures may be These procedures include
required. See references to these references to the tools required.
procedures in the step-by-step
instructions below.

Removal parallel arm


The procedure below details how to remove the parallel arm.

3HAC 022031-001 Revision: A 135


4 Repair
4.6.5. Removal of the parallel arm

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Step Action Note/Illustration


1. Loosen the tie rod Described in chapterRemoval of the tie rod on
page 117
2. Remove the parallel arm

136 3HAC 022031-001 Revision: A


4 Repair
4.6.6. Reassemble of the parallel arm

4.6.6. Reassemble of the parallel arm

Location of parallel arm


The parallel arm is located as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000444

A Tie rod
B Parallel arm

Required equipment

Spare
Equipment, etc. Art. no. Note
part no.
Groove ball bearing 3HAB 3643-12 61822-2RS1
Sealing V-ring 3HAB 5515-1 Acetal (POM)
Bearing grease 3HAB 3537-1 1g
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!

3HAC 022031-001 Revision: A 137


4 Repair
4.6.6. Reassemble of the parallel arm

Spare
Equipment, etc. Art. no. Note
part no.
Special toolkit
Other tools and These procedures include references to
procedures may be the tools required.
required. See
references to these
procedures in the
step-by-step
instructions below.

Assembly
The procedure below details how to assemble the sealing, bearing and how do mount parallel
arm on the robot.

xx0200000450

A Parallel arm
B Sealing V- ring
C Groove ball bearing
D Screw (hex.socket head cap )

NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.

138 3HAC 022031-001 Revision: A


4 Repair
4.6.6. Reassemble of the parallel arm

Step Action Note/Illustration


1. Mount V-ring (B) on the parallel arm (A)
2. Fit a new bearing to the parallel arm. NOTE! Heat up the bearing to 170 C°
before mounting it on the parallel arm.
3. Mount the other V-ring (B) on the parallel arm
(A)
4. Replace the screws and tighten. Torque of 72 Nm.
5. Mount the tie rod. Described in chapterReassemble of
the tie rod on page 120

3HAC 022031-001 Revision: A 139


4 Repair
4.7.1. Removal of motor, axis 1

4.7 Motors

4.7.1. Removal of motor, axis 1

Location of motor axis 1


The motor axis 1 is located on the left hand side of the manipulator as shown in the figure
below:
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000465

A Cover
B Connection box
C Screw + Spring washer
D Motor axis 1
E Position mark

140 3HAC 022031-001 Revision: A


4 Repair
4.7.1. Removal of motor, axis 1

Required equipment

Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the Product
manual, reference information.

Removal
The procedure below details how to remove motor, axis 1.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!

Step Action Note/Illustration


1. Remove the cover of the connection Shown in figure in section Location of motor
box axis 1 on page 140
2. Loosen connectors R3.MP1 and
R3.FB1

xx0200000406

• A: R3.MP1
• B: R3.FB1
• C: Connection box
3. Remove the Connection box by
unscrewing its three attachment
screws and plain washers.

3HAC 022031-001 Revision: A 141


4 Repair
4.7.1. Removal of motor, axis 1

Step Action Note/Illustration


4. Use a marker pen to mark out the Shown in figure in sectionLocation of motor
position of the motor axis 1 on page 140
5. Remove the motor by unscrewing its
four attachment screws and plain
washers.
6. Remove the motor by gently lifting it Shown in figure in section Location of motor
straight up. axis 1 on page 140

142 3HAC 022031-001 Revision: A


4 Repair
4.7.2. Refitting of motor, axis 1

4.7.2. Refitting of motor, axis 1

Location of motor axis 1


The motor axis 1 is located on the left hand side of the manipulator as shown in the figure
below:
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000465

A Cover
B Connection box
C Screws
D Motor axis 1
E Marking
F O-ring

3HAC 022031-001 Revision: A 143


4 Repair
4.7.2. Refitting of motor, axis 1

Required equipment

Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
Gasket 3HAB 3676-1
O-ring 3HAB 3772-1
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.

Removal
The procedure below details how to refit motor, axis 1.

Step Action Note/Illustration


1. Check that the assembly surfaces are
clean and the motor unscratched
2. Mount the O-ring Always mount a new one, see art. no. in
section Location of motor axis 1 on page 143
3. Install the motor, by gently lifting it
straight on
4. Tighten the four screws Note the position of the motor! use the mark
on the motor foot, shown in figure in
sectionLocation of motor axis 1 on page 143
2 Nm
5. Refit the Connection box by assemble
the three attachment screws and plain
washers.
6. Reconnect connectors R3.MP1 and
R3.FB1

xx0200000406

• A: R3.MP1
• B: R3.FB1
• C: Connection box
7. Refit the cover of the connection box Shown in figure in sectionLocation of motor
axis 1 on page 143

144 3HAC 022031-001 Revision: A


4 Repair
4.7.3. Removal of motor, axis 2

4.7.3. Removal of motor, axis 2

Location of motor axis 2


The motor axis 2 is located on the left hand side of the manipulator as shown in the figure
below:
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000470

A Torx screw
B Cover
C Connection box
D Gasket
E Motor 2
F Screw
G O-ring

3HAC 022031-001 Revision: A 145


4 Repair
4.7.3. Removal of motor, axis 2

Required equipment

Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the Product
manual, reference information.

Removal, motor axis 2


The procedure below details how to remove motor, axis 2.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.
WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!

146 3HAC 022031-001 Revision: A


4 Repair
4.7.3. Removal of motor, axis 2

Step Action Note/Illustration


1. Remove the cover of the connection Shown in figure in section Location of motor
box axis 2 on page 145
2. Loosen connectors R3.MP2 and
R3.FB2

xx0200000401

• A: R3.MP2
• B: R3.FB2
• C: Connection box
3. Remove the Connection box by
unscrewing its three attachment
screws and plain washers.
4. Use a marker pen to mark out the Shown in figure in sectionLocation of motor
position of the motor axis 2 on page 145
5. Secure the upper arm before
unscrewing any of the motor
attachment screws.

xx0300000107

6. Remove the motor by unscrewing its


four attachment screws and plain
washers.
WARNING! The oil in the gear house
leaks out when the motor is removed.
7. Remove the motor by gently lifting it Shown in figure in section Location of motor
straight out. axis 2 on page 145

3HAC 022031-001 Revision: A 147


4 Repair
4.7.4. Refitting of motor, axis 2

4.7.4. Refitting of motor, axis 2

Location of motor axis 2


The motor axis 2 is located on the left hand side of the manipulator as shown in the figure
below:
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000470

A Torx screw
B Cover
C Connection box
D Gasket
E Motor 2
F Screw
G O-ring

148 3HAC 022031-001 Revision: A


4 Repair
4.7.4. Refitting of motor, axis 2

Required equipment

Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
Gasket 3HAB 3676-1
O-ring 3HAB 3772-1
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
Mounting tool 3HAB 7887-1

Refit motor 2
The procedure below details how to refit motor, axis 2.
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!

Step Action Note/Illustration


1. Check that the assembly surfaces are
clean and the motor unscratched.
2. Fit the O-ring. Always fit a new one, see art. no. in
section Location of motor axis 2 on page
148
3. Install the motor, by gently lifting it straight
on.
4. Tighten the four screws. Note the position of the motor! use the
mark on the motor foot, shown in figure in
section.Location of motor axis 2 on page
148
2 Nm.
5. Release the brake by applying 24 VDC to
terminals 7(+) and 8 in the R3.MP1
connector.

3HAC 022031-001 Revision: A 149


4 Repair
4.7.4. Refitting of motor, axis 2

Step Action Note/Illustration


6. Fit the tool at the rear of the motor. See figure below.
Tool No. 3HAB 7887-1 at
7. Turn the motor shaft a couple of turns, See figure below.
with help of the tool.
8. Place the tip of a dial indicator against the The tip of the dial indicator must measure
scribed mark on the measuring tool. on a 50 mm radius from the centre of the
motor shaft .
Se figure below.
9. Set the gear play to 0.02 mm, which
corresponds to a reading on the dial
indicator of 0.13 mm.

xx0200000473

• A: Mount tool No. 3HAB 7887-1


10. Pull gently in one direction. Note the See figure above.
reading. (The gear must not turn.)
11. Then gently knock on the tool in the other See figure above.
direction and note the reading. The
difference in reading = gear play. The gear
play should be 0.02 mm which
corresponds to a reading on the dial
indicator of 0.13 mm.
12. Tighten screws <1/8, 1/9>. 23 Nm
13. Fill with oil.
14. Refit the Connection box by assembling
the three attachment screws and plain
washers.

150 3HAC 022031-001 Revision: A


4 Repair
4.7.4. Refitting of motor, axis 2

Step Action Note/Illustration


15. Reconnect connectors R3.MP2 and
R3.FB2.

xx0200000401

• A: R3.MP2
• B: R3.FB2
• C: Connection box
16. Refit the cover of the connection box. Shown in figure in sectionLocation of
motor axis 2 on page 148
17. Calibrate the robot. Calibration is detailed in separate
calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.

3HAC 022031-001 Revision: A 151


4 Repair
4.7.5. Removal of motor, axis 3

4.7.5. Removal of motor, axis 3

Location of motor axis 3


The motor axis 3 is located on the right hand side of the manipulator as shown in the figure
below:
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000471

A Torxs screw
B Cover
C Connection box
D Gasket
E Motor 2
F Screw
G O-ring

152 3HAC 022031-001 Revision: A


4 Repair
4.7.5. Removal of motor, axis 3

Required equipment

Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference information.

Removal, motor axis 3


The procedure below details how to remove motor, axis 3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!

Step Action Note/Illustration


1. Remove the cover of the connection Shown in figure in section Location of motor axis
box 3 on page 152
2. Loosen connectors R3.MP3 and
R3.FB3

xx0200000401

• A: R3.MP3
• B: R3.FB3
• C: Connection box
3. Remove the Connection box by
unscrewing its three attachment
screws and plain washers.

3HAC 022031-001 Revision: A 153


4 Repair
4.7.5. Removal of motor, axis 3

Step Action Note/Illustration


4. Use a marker pen to mark out the Shown in figure in sectionLocation of motor axis
position of the motor 3 on page 152
5. Secure the upper arm before
loosening any of the screws on the
motor.

xx0300000107

6. Remove the motor by unscrewing


its four attachment screws and plain
washers.
WARNING! The oil in the gear
house leaks out when the motor is
removed
7. Remove the motor by gently lifting it Shown in figure in section Location of motor axis
straight out. 3 on page 152

154 3HAC 022031-001 Revision: A


4 Repair
4.7.6. Refitting of motor, axis 3

4.7.6. Refitting of motor, axis 3

Location of motor axis 3


The motor axis 3 is located on the left hand side of the manipulator as shown in the figure
below:
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000471

A Torx screw
B Cover
C Connection box
D Gasket
E Motor 2
F Screw
G O-ring

3HAC 022031-001 Revision: A 155


4 Repair
4.7.6. Refitting of motor, axis 3

Required equipment

Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures These procedures include references
may be required. See to the tools required.
references to these
procedures in the step-by-
step instructions below.
Gasket 3HAB 3676-1
O-ring 3HAB 3772-1
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.
Mounting tool 3HAB 7887-1

Refitt motor 3
The procedure below details how to refitt motor, axis 3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.

Step Action Note/Illustration


1. Check that the assembly surfaces are
clean and the motor unscratched.
2. Mount the O-ring. Always mount a new one, see art. no. in
section Required equipment on page 156
3. Install the motor, by gently lifting it
straight on.

156 3HAC 022031-001 Revision: A


4 Repair
4.7.6. Refitting of motor, axis 3

Step Action Note/Illustration


4. Tighten the four screws using a torque Note the position of the motor! Use the
of 2 Nm. mark on the motor foot, shown in figure in
section.Refitting of motor, axis 1 on page
143
5. Release the brake by applying 24 V d.c.
to terminals 7(+) and 8 in the R3.MP3
connector.
6. Mount tool No. 3HAB 7887-1 at the rear See figure below.
of the motor.
7. Turn the motor shaft a couple of turns, See figure below.
with help of the tool.
8. Place the tip of a dial indicator against The tip of the dial indicator must measure
the scribed mark on the measuring tool. on a 50 mm radius from the center of the
motor shaft .
Se figure below.
9. Set the gear play to 0.02 mm, which
corresponds to a reading on the dial
indicator of 0.13 mm.

xx0200000473

• A: Mount tool No. 3HAB 7887-1


10. Pull gently in one direction. Note the See figure abowe
reading. (The gear must not turn.)
11. Then gently knock on the tool in the See figure abowe
other direction and note the reading.
The difference in reading = gear play.
The gear play should be 0.02 mm which
corresponds to a reading on the dial
indicator of 0.13 mm
12. Tighten the motor attachment screws. 23 Nm
13. Fill with oil. See the chapter, Section Oil Change in
Gearboxes in maintenance manual
14. Refit the Connection box by assembling
the three attachment screws and plain
washers.

3HAC 022031-001 Revision: A 157


4 Repair
4.7.6. Refitting of motor, axis 3

Step Action Note/Illustration


15. Reconnect connectors R3.MP3 and
R3.FB3.

xx0200000401

• A: R3.MP3
• B: R3.FB3
• C: Connection box
16. Refitt the cover of the connection box. Shown in figure in sectionRefitting of motor,
axis 1 on page 143
17. Calibrate the robot. Calibration is detailed in separate
calibration manuals.
Art. no. for the manuals are specified in
section Document references in the
Product manual, reference information.

158 3HAC 022031-001 Revision: A


4 Repair
4.7.7. Removal of motor, axis 4-6;IRB 2400L

4.7.7. Removal of motor, axis 4-6;IRB 2400L

Location of motor axis 4-6


The motor axis 4 is located on the right hand side of the manipulator as shown in the figure
below:
The motor axis 5-6 is located on the back side of the manipulator as shown in the figure
below:
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000476

A Torx screw
B Cover
C Connection box
D Screw
E Motor 6
F Motor 5
G Motor 4
H Gearbox

Required equipment

Spare Art.
Equipment, etc. ote
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.

3HAC 022031-001 Revision: A 159


4 Repair
4.7.7. Removal of motor, axis 4-6;IRB 2400L

Removal, motor axis 5-6 (5 kg)


The procedure below details how to remove motor, axis 4-6.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• - Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
• - Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• - Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. securing the lower arm with fixtures before removing motor,
axis 2.
NOTE!
Whenever mating motor and gearbox, misalignment of the gears may severely damage them.
Avoid this risk:
• Fit the gearbox.
• Turn the gears of the gearbox to the correct position using the gearbox crank. The part
number is specified in the table above!
• Fit the motor.
NOTE!
• - Before removing, clean the work area and the components to be removed.
• - Place the removed components in a clean container.

Step Action Note/Illustration


1. Remove the cover of the Shown in figure in section Location of motor axis
connection box 4-6 on page 159
2. Loosen connectors R3.MP5-6 and
R3.FB5-6

xx0300000063

3. Remove the Connection box by


unscrewing its three attachment
screws and plain washers.

160 3HAC 022031-001 Revision: A


4 Repair
4.7.7. Removal of motor, axis 4-6;IRB 2400L

Step Action Note/Illustration


4. Use a marker pen to mark out the Shown in figure in section Location of motor axis
position of the motors 4-6 on page 159
5. Remove the motor by unscrewing
its attachment screws and plain
washers.
6. Remove the motors by gently lifting Shown in figure in section Location of motor axis
them straight up (horizontal 4-6 on page 159
movement).

Removal, motor axis 4 (5 kg)


The procedure below details how to remove motor, axis 4.

Step Action Note/Illustration


1. Remove the cover of the
connection box.

xx0200000401

• A: R3.MP4
• B: R3.FB4
• C: Case
2. Loosen connectors R3.MP4 and Shown in figure above.
R3.FB4.
3. Remove the Connection box by
unscrewing its three attachment
screws and plain washers.
4. Use a marker pen to mark out
the position of the motors.
5. Remove the motor by
unscrewing its attachment
screws and plain washers.
WARNING! The gearbox is filled
with oil, to avoid oil from leaking
when dismounting the motors,
drain the oil from the gearbox.
6. Remove the motors by gently
lifting them straight up
(horizontal movement).

3HAC 022031-001 Revision: A 161


4 Repair
4.7.8. Refitting of motor, axis 4-6

4.7.8. Refitting of motor, axis 4-6

Location of motor axis 4-6


The motor axis 4 is located on the right hand side of the manipulator as shown in the figure
below:
The motor axis 5-6 is located on the back side of the manipulator as shown in the figure
below:
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0200000476

A Torx screw
B Cover
C Connection box
D Screw
E Motor 6
F Motor 5
G Motor 4
H Gearbox

Required equipment

Spare
Equipment, etc. Art. no. Note
part no.
O-ring 3HAB 3772-1 3 pcs
Loctite 243 3HAB 7116-1
Bearing grease 3HAB 3537-1
Mount tool 3HAB 7887-1
Lubricating oil 1171 2016-604
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!

162 3HAC 022031-001 Revision: A


4 Repair
4.7.8. Refitting of motor, axis 4-6

Spare
Equipment, etc. Art. no. Note
part no.
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference
information.

Reassemble of motor axis 4


The procedure below details how to reassemble motor, axis 4.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!

Step Action Note/Illustration


1. Check that the assembly surfaces
are clean and the motor unscratched
2. Mount a new O-ring on the motor. 3HAB 3772-1
3. Grease the gear with bearing grease 3HAB 3537-1

3HAC 022031-001 Revision: A 163


4 Repair
4.7.8. Refitting of motor, axis 4-6

Step Action Note/Illustration


4. Mount the tool at the rear of the
motor.

xx0300000005

• A: Tool no. 3HAB 7887-1


5. The motor’s fixing screws shall be
fastened, but do not tighten them, to
ensure that the motor will be able to
move parallel to the gear when the
adjustment is done
6. Release the brake, apply 24 V DC to
terminals 7 and 8 on the R3.MP4
connectors
7. Start with a play in all positions and
then locate the smallest play by
turning the motor shaft 6 turns and
thereby find the area with the
smallest play within this range. Use
swift movements to avoid noticing
the magnetic field, which makes the
gears stick together.
8. Push or tap the motor in radial
direction so that the play becomes
minimal within one motor turn,
without the gear “chewing”. Do not
use force!
9. Tighten the motor attachment 4.1 Nm
screws and secure them with locking Loctite 243
fluid.
10. Fill with oil. 30ml
11. Connect the cabling. Described in Refitting of cable harness on
page 84.
12. Calibrate the robot. Calibration is detailed in separate calibration
manuals.
Art. no. for the manuals are specified in section
Document references in the Product manual,
reference information.

164 3HAC 022031-001 Revision: A


4 Repair
4.7.8. Refitting of motor, axis 4-6

Reassemble of motor axis 5


The procedure below details how to reassemble motor, axis 5.

Step Action Note/Illustration


1. Check that the assembly surfaces are clean and the
motor unscratched
2. Fit a new O-ring on the motor. 3HAB 3772-1
3. Fit the tool at the rear of the motor. Look at the figure in section
Reassemble of motor axis 4
on page 163
Tool no. 3HAB7887-1.
4. The motor’s fixing screws shall be fastened, but do
not tighten them, to ensure that the motor will be able
to move parallel to the gear when the adjustment is
done
5. Release the brake, apply 24 V DC to terminals 7 and
8 on the R3.MP5 connectors
6. Locate the smallest play by turning the outgoing shaft
for axis 4 in intervals of 90°, one full turn, and thereby
find the area where the play for motor 5 becomes
smallest. Turn the motor for axis 5 one full turn at a
time for a total of 5 turns. Find where the smallest play
is within this area. Use swift movements to avoid
noticing the magnetic field, which makes the gears
stick together.
7. Push or tap the motor in radial direction so that the
play becomes minimal within one motor turn, without
the gear “chewing”. Do not use force!
8. Tighten the motor attachment screws and secure 4.1 Nm
them with locking fluid. Loctite 243
9. Connect the cabling. Described in Refitting of
cable harness on page 84.
10. Calibrate the robot Calibration is detailed in
separate calibration
manuals.
Art. no. for the manuals are
specified in section
Document references in the
Product manual, reference
information.

Reassemble of motor axis 6


The procedure below details how to reassemble motor, axis 6.

Step Action Note/Illustration


1. Check that the assembly surfaces are clean and the
motor unscratched
2. Fit an new O-ring on the motor. 3HAB 3772-1

3HAC 022031-001 Revision: A 165


4 Repair
4.7.8. Refitting of motor, axis 4-6

Step Action Note/Illustration


3. Fit the tool at the rear of the motor. Look at the figure in section
Reassemble of motor axis 4
on page 163.
Tool no. 3HAB7887-1.
4. The motor’s fixing screws shall be fastened, but do
not tighten them, to esure that the motor will be able
to move parallel to the gear when the adjustment is
done
5. Release the brake, apply 24 V DC to terminals 7 and
8 on the R3.MP6 connectors
6. Seek up the smallest play by turning the outgoing
shaft for axis 4 in intervals of 90°, totally one whole
turn, and thereby find the area where the play for
motor 6 becomes smallest. Turn the motor for axis 5
one full turn at the time, totally 5 turns. Find the
smallest play for axis 6 within this area. Turn the
motor for axis 6 one full turn at a time for a time for a
total of 3 turns. Find the smallest play for axis 6 within
this area. Use swift movements to avoid noticing the
magnetic field, which makes the gears stick together
7. Push or tap the motor in radial direction so that the
play becomes minimal within one motor turn, without
the gear “chewing”. Do not use force!
8. Tighten the motor attachment screws and secure 4.1 Nm.
them with locking fluid. Loctite 243
9. Connect the cabling. Described in Refitting of
cable harness on page 84
10. Calibrate the robot Calibration is detailed in
separate calibration
manuals.
Art. no. for the manuals are
specified in section
Document references in the
Product manual, reference
information.

166 3HAC 022031-001 Revision: A


4 Repair
4.7.9. Removal of motor, axis 4-6, IRB 2400/10/16

4.7.9. Removal of motor, axis 4-6, IRB 2400/10/16

Location of motor axis 4-6


The motor axis 4-6 is located on the back of the manipulator as shown in the figure below:
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0300000108

A Torx screw
B Cover
C Connection box
D Screw
E Motor 6
F Motor 5
G Motor 4
H Gearbox

Required equipment

Spare
Equipment, etc. Art. no. Note
part no.
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!
Other tools and procedures may These procedures include
be required. See references to references to the tools
these procedures in the step-by- required.
step instructions below.

Removal, motor axis 4-6 (10/16 kg)


The procedure below details how to remove motor, axis 4-6.

3HAC 022031-001 Revision: A 167


4 Repair
4.7.9. Removal of motor, axis 4-6, IRB 2400/10/16

WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.

Step Action Info/Illustration


1. Remove the cover of the connection Shown in figure in section xx.
box
2. Loosen connectors R3.MP4-6 and
R3.FB4-6

xx0200000406

• A: R3.MP5
• B: R3.MP6
• C: R3.MP4
• D: R3.FB5
• E: R3.FB6
• F: R3.FB4
3. Remove the Connection box by
unscrewing its three attachment screws
and plain washers.
4. Use a marker pen to mark out the
position of the motors

168 3HAC 022031-001 Revision: A


4 Repair
4.7.9. Removal of motor, axis 4-6, IRB 2400/10/16

Step Action Info/Illustration


5. Remove the motor by unscrewing its
attachment screws and plain washers.
WARNING! The gearbox is filled with
oil, to avoid leak when dismounting
the motors, drain the oil from the
gearbox.
6. Remove the motors by gently lifting
them straight out (horizontal
movement).

3HAC 022031-001 Revision: A 169


4 Repair
4.7.10. Refitting of motor, axis 4-6 IRB 2400/10/16

4.7.10. Refitting of motor, axis 4-6 IRB 2400/10/16

Location of motor axis 4-6


The motor axis 4-6 is located on the back of the manipulator as shown in the figure below:
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0300000108

A Torx screw
B Cover
C Connection box
D Screw
E Motor 6
F Motor 5
G Motor 4
H Gearbox

Required equipment

Spare
Equipment, etc. Art. no. Note
part no.
O-ring 3HAB 3772-1
Loctite 243 3HAB 7116-1
Bearing grease 3HAB 3537-1
Mount tool 3HAB 7887-1
Lubricating oil 1171 2016-604
Standard toolkit The contents are defined in
section Standard toolkit in the
Product manual, reference
information!

170 3HAC 022031-001 Revision: A


4 Repair
4.7.10. Refitting of motor, axis 4-6 IRB 2400/10/16

Spare
Equipment, etc. Art. no. Note
part no.
Other tools and procedures These procedures include
may be required. See references to the tools
references to these procedures required.
in the step-by-step instructions
below.
Reused screws may be used,
providing they are lubricated as
detailed in Screw Joints before
fitting.
Circuit Diagram 3HAC 6670-3 See chapter Circuit diagram in
the Product manual, reference
information.

Reassemble of motor axis 4


The procedure below details how to reassemble motor, axis 4.

Step Action Info/Illustration


1. Check that the assembly surfaces are
clean and the motor unscratched
2. Fit a new O-ring on the motor. 3HAB 3772-1
3. Grease the gear with bearing grease 3HAB 3537-1
4. Fit the tool at the rear of the motor.

xx0300000005

Tool no. 3HAB 7887-1


5. The motor’s fixing screws shall be
fastened, but do not tighten them, to be
sure that the motor will be able to move
parallel to the gear when the adjustment
is done
6. Release the brake, apply 24 V DC to
terminals 7 and 8 on the R3.MP4
connectors

3HAC 022031-001 Revision: A 171


4 Repair
4.7.10. Refitting of motor, axis 4-6 IRB 2400/10/16

Step Action Info/Illustration


7. Start with a play in all positions and then
seek up the smallest play by turning the
motor shaft 6 turns and thereby find the
area with the smallest play within this
range. Use swift movements to avoid
noticing the magnetic field, which
makes the gears stick together.
8. Push or tap the motor in radial direction
so that the play becomes minimal within
one motor turn, without the gear
“chewing”. Do not use force!
9. Tighten the motor attachment screws 4.1 Nm.
and secure them with locking fluid. Loctite 243
10. Fill the gearbox whith the proper 1.5 litres (0.4 US gallon)
quantity of oil
11. Connect the cabling. Described in Refitting of cable harness on
page 84

Reassemble of motor axis 5


The procedure below details how to reassemble motor, axis 5.

Step Action Note/Illustration


1. Check that the assembly surfaces are clean and the
motor unscratched
2. Fit a new O-ring on the motor. 3HAB 3772-1
3. Mount the tool at the rear of the motor. Tool no. 3HAB7887-1
4. The motor’s fixing screws shall be fastened, but do
not tighten them, to be sure that the motor will be able
to move parallel to the gear when the adjustment is
done
5. Release the brake, apply 24 V DC to terminals 7 and
8 on the R3.MP5 connectors
6. Seek up the smallest play by turning the outgoing
shaft for axis 4 in intervals of 90°, one full turn, and
thereby find the area where the play for motor 5
becomes smallest. Turn the motor for axis 5 one full
turn at a time for a total of 5 turns. Find where the
smallest play is within this area. Use swift movements
to avoid noticing the magnetic field, which makes the
gears stick together.
7. Push or tap the motor in radial direction so that the
play becomes minimal within one motor turn, without
the gear “chewing”. Do not use force!
8. Tighten the motor attachment screws and secure 4.1 Nm.
them with locking fluid. Loctite 243
9. Connect the cabling. Described in Refitting of
cable harness on page 84

Reassemble of motor axis 6


The procedure below details how to reassemble motor, axis 6.

172 3HAC 022031-001 Revision: A


4 Repair
4.7.10. Refitting of motor, axis 4-6 IRB 2400/10/16

Step Action Note/Illustration


1. Check that the assembly surfaces are clean and the
motor unstructured.
2. Fit a new O-ring on the motor. 3HAB 3772-1
3. Fit the tool at the rear of the motor. Tool no. 3HAB 7887-1.
4. The motor’s fixing screws shall be fastened, but do
not tighten them, to be sure that the motor will be able
to move parallel to the gear when the adjustment is
done
5. Release the brake, apply 24 V DC to terminals 7 and
8 on the R3.MP6 connectors
6. Seek up the smallest play by turning the outgoing
shaft for axis 4 in intervals of 90°, one full turn, and
thereby find the area where the play for motor 6
becomes smallest. Turn the motor for axis 5 one full
turn at the time, totally 5 turns. Find the smallest play
for axis 6 within this area. Turn the motor for axis 6
one full turn at a for a total of 3 turns. Find the smallest
play for axis 6 within this area. Use swift movements
to avoid noticing the magnetic field, which makes the
gears stick together
7. Push or tap the motor in radial direction so that the
play becomes minimal within one motor turn, without
the gear “chewing”. Do not use force!
8. Tighten the motor attachment screws and secure 4.1 Nm.
them with locking fluid. Loctite 243
9. Fill the gearbox with the proper quantity of oil 0.8 litres (0.2 US gallon) total
for 5 and 6.
10. Connect the cabling. Described in Refitting of
cable harness on page 84.
11. Calibrate the robot. Calibration is detailed in
separate calibration
manuals.
Art. no. for the manuals are
specified in section
Document references in the
Product manual, reference
information.

3HAC 022031-001 Revision: A 173


4 Repair
4.8.1. Removal of gearbox, axis 1-3

4.8 Gearboxes

4.8.1. Removal of gearbox, axis 1-3

Location of gearbox axis 1-3


The axis 1 gearbox is located between the frame and base as shown in the figure below.
Axis 1 gearbox is of the conventional type, manufactured with high precision, and together
with the gearboxes for axes 2 and 3, forms a complete unit.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.
The gearbox is not normally serviced or adjusted.

xx0300000007

A M12x50 8.8 hexagon socket head cap screw


B Cover

Required equipment

Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures may be These procedures include
required. See references to these references to the tools required.
procedures in the step-by-step
instructions below.

174 3HAC 022031-001 Revision: A


4 Repair
4.8.1. Removal of gearbox, axis 1-3

Removal
The procedure below details how to remove gearbox, axis 1-3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.

Step Action Note/Illustration


1. Remove the complete lower arm. Detailed in Removal of complete lower
arm on page 110.
2. Remove the motor, axis 1. Detailed inRemoval of motor, axis 1 on
page 140.
3. Remove the motor, axis 2. Detailed in Removal of motor, axis 2 on
page 145.
4. Remove the motor, axis 3. Detailed in Removal of motor, axis 3 on
page 152.
5. Place the remaining parts of the manipulator
upside-down on a table or similar surface
and remove the bottom plate.
6. Undo all 12, M12 hex. sock. screws

3HAC 022031-001 Revision: A 175


4 Repair
4.8.2. Refitting of gearbox, axis 1-3

4.8.2. Refitting of gearbox, axis 1-3

Location of gearbox axis 1-3


The axis 1 gearbox is located between the frame and base as shown in the figure below.
Axis 1 gearbox is of the conventional type, manufactured with high precision, and together
with the gearboxes for axes 2 and 3, forms a complete unit.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.
The gearbox is not normally serviced or adjusted.

xx0300000007

A M12x50 8.8 hexagon socket head cap screw


B Cover

Required equipment

Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product
manual, reference information!
Other tools and procedures may be These procedures include
required. See references to these references to the tools required.
procedures in the step-by-step
instructions below.

176 3HAC 022031-001 Revision: A


4 Repair
4.8.2. Refitting of gearbox, axis 1-3

Refitting
The procedure below details how to refit gearbox, axis 1-3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.

Step Action Note/Illustration


1. Fit and secure the 12 screws 54 Nm.
complete with washers .
2. Place the gearbox upside-down
on a table or similar surface and
refit the bottom plate
3. Refit the motor, axis 1. Detailed in Refitting of motor, axis 1 on page
143.
4. Refit the motor, axis 2. Detailed in Refitting of motor, axis 2 on page
148.
5. Refit the motor, axis 3. Detailed in Refitting of motor, axis 3 on page
155.
6. Refit the complete lower arm. Detailed in Refitting of complete lower arm on
page 114.
7. Calibrate the robot. Calibration is detailed in separate calibration
manuals.
Art. no. for the manuals are specified in section
Document references in the Product manual,
reference information.

3HAC 022031-001 Revision: A 177


4 Repair
4.8.3. Remove the complete drive mechanism. IRB 2400L

4.8.3. Remove the complete drive mechanism. IRB 2400L

Location
The drive mechanism is defined as the gears and drive belts to axes 5 and 6. This is shown in
the figure below.

xx0300000012

Required equipment

Spare Art.
Equipment, etc. Note
part no. no.
Standard toolkit The contents are defined in section
Standard toolkit in the Product manual,
reference information!
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these
procedures in the step-by-
step instructions below.

Removal
The procedure below details how to remove the Drive Shaft Unit from the robot upper arm.
NOTE! ABB recommends its customers to carry out only the following servicing and repair
work on the Drive Shaft Unit.

178 3HAC 022031-001 Revision: A


4 Repair
4.8.3. Remove the complete drive mechanism. IRB 2400L

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
NOTE!
• Before removing, clean the work area and the components to be removed.
• Place the removed components in a clean container.

Step Action Note/Illustration


1. Dismantle the wrist Described in section Removal of wrist
IRB 2400/10/16. on page 93.
2. Loosen the connection box and disconnect Described in section Removal of motor,
the connectors on the motors of axes 5 axis 4-6;IRB 2400L on page 159.
and 6. Make a note of the motor No. on the
motors, to simplify the reconnecting.
3. Undo screws

xx0300000021

• A: Screws
• B: Motor screws
4. Squeeze the drive shafts together at the tip
of the tubular shaft, so they can pass
through the tube
5. Pull out the complete drive mechanism of
axes 5 and 6.
6. Undo the screws and nuts , holding the Described in section Removal of motor,
motors and remove both motors. axis 4-6;IRB 2400L on page 159.
7. Undo the screws and remove the motor
plate.
8. Remove the gear belts.

3HAC 022031-001 Revision: A 179


4 Repair
4.8.4. Refitting of complete drive mechanism. IRB 2400L

4.8.4. Refitting of complete drive mechanism. IRB 2400L

Location
The drive mechanism is defined as the gears and timing belts to axis 5 and 6. This is shown
in the figure below.

xx0300000012

Required equipment

Spare
Equipment, etc. Art. no. Note
part no.
Lifting device, manipulator
Standard toolkit The contents are defined
in section Standard toolkit
in the Product manual,
reference information!
Other tools and procedures may These procedures include
be required. See references to references to the tools
these procedures in the step-by- required.
step instructions below.
New timing belt 3HAA 2393-1 2 pcs
Mounting Tool 3HAA 7601-050

Location
The procedure below details how to remove the Drive Shaft Unit from the robot upper arm.
NOTE! ABB recommends its customers to carry out only the following servicing and repair
work on the Drive Shaft Unit.

180 3HAC 022031-001 Revision: A


4 Repair
4.8.4. Refitting of complete drive mechanism. IRB 2400L

WARNING!
Please observe the following before commencing any repair work on the manipulator:
• Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
• Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
• Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Please observe the following when refitting components:
• Carefully clean the connecting surfaces.
• Ensure that there are no damaged surfaces or other parts that need rectifying or
replacing.
• Replace all gaskets.

Step Action Note/Illustration


1. Install the belts.
2. Fit the plate using screws and N.B. Do not forget the nuts on the motors!
washers.
3. Fit the motors.
4. Push the motors sideways to tighten Tool no. 3HAA 7601-050.
the belts, using the tool. Place the Tighten screws B (shown in the illustration
round post of the tool into the motor below) to 4.1 Nm.
pulley and let the cam press to the
outer diameter of the large pulley.
5. Rotate the drive shafts. Check the
tension on the belt.
6. Install the drive mechanism in the Do not forget the rubber damper.
tubular shaft.
7. Tighten screws.

xx0300000021

• A: 8.3 Nm
8. Install the cabling and mount the Detailed in Refitting of motor, axis 4-6 on page
cover to motors axes 5 and 6. 162
9. Mount the wrist. Described in sectionRefitting of wrist IRB
2400/10/16 on page 96
10. Calibrate the robot. Calibration is detailed in separate calibration
manuals.
Art. no. for the manuals are specified in
section Document references in the Product
manual, reference information.

3HAC 022031-001 Revision: A 181


4 Repair
4.8.4. Refitting of complete drive mechanism. IRB 2400L

182 3HAC 022031-001 Revision: A


5 Calibration information
5.1. Introduction

5 Calibration information
5.1. Introduction

General
This chapter includes general information about different calibration methods and details also
procedures that does not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.

When to calibrate
The system must be calibrated if any of the below occurs.

The resolver values are changed


If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied from ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in section Calibration methods on page 184, and further
detailed in separate Calibration manuals.
If the robot has Absolute Accuracy calibration, it is also recommended but not always needed
to be calibrated for new Absolute Accuracy.
The resolver values will change when parts affecting the calibration position are replaced on
the robot, e.g. motors, wrist or part of transmission.

Contents of the revolution counter memory are lost


If the contents of the revolution counter memory are lost, the counters must be updated as
detailed in section Updating revolution counters on page 189. This will occur when:
• the battery is discharged
• a resolver error occurs
• the signal between a resolver and measurement board is interrupted
• a robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are connected at
the first installation.

The robot is rebuilt


If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other
reachability, it needs to be recalibrated for new resolver values.
If the robot has Absolute Accuracy calibration, it needs to be calibrated for new Absolute
Accuracy.

References
The article numbers for the Calibration manuals are listed in section Document references in
the Product manual (part 2 of 2), reference information. Article numbers for the calibration
tools are also listed in part 2 of the Product manual.

3HAC 022031-001 Revision: A 183


5 Calibration information
5.2. Calibration methods

5.2. Calibration methods

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

Types of calibration

Type of
Description Calibration method
calibration
Standard The calibrated robot is positioned at home Calibration Pendulum
calibration position, i.e. the axes positions (angles) are (standard method)
set to 0º. or
Standard calibration data is found in the file Levelmeter calibration
calib.cfg, supplied with the robot at delivery. (alternative method)
The file identifies the correct resolver/motor
position corresponding to the robot home
position.
From deliveries together with RobotWare 5.0.5
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
Absolute Accuracy Based on standard calibration, but besides CalibWare
calibration positioning the robot at home position, the
(optional) Absolute Accuracy calibration also
compensates for:
• mechanical tolerances in the robot
structure
• deflection due to load.
Absolute Accuracy calibration focuses on
positioning accuracy in the Cartesian
coordinate system for the robot.
Absolute Accuracy data is found in the file
absacc.cfg, supplied with the robot at delivery.
The file replaces the calib.cfg file and identifies
motor positions as well as absacc-
compensation parameters.
From deliveries together with RobotWare 5.0.6
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
A robot calibrated with AbsAcc has a sticker
next to the identification plate of the robot.
To regain 100% Absolute Accuracy
performance, the robot must be recalibrated
for Absolute Accuracy!

xx0400001197

184 3HAC 022031-001 Revision: A


5 Calibration information
5.2. Calibration methods

Calibration methods
Each calibration method is detailed in separate manuals. Below is a brief description of the
methods available.

Calibration Pendulum - standard method


Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB
6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the
standard type of calibration. It is the recommended method in order to achieve proper
performance.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including the manual Calibration Pendulum Instruction.

Levelmeter Calibration - alternative method


Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots,
because of the less accurate values obtained during calibration. The method uses the same
principles as Calibration Pendulum but has not as good mechanical tolerances to the toolkit
parts as the standard method with Calibration Pendulum.
This method may, after calibration, require modifications in the robot program, and is therefor
not recommended.
The calibration equipment for Levelmeter Calibration is ordered as separate parts for each
robot and the manual Instruction for Levelmeter Calibration is enclosed with the Levelmeter
2000.

CalibWare - Absolute Accuracy calibration


In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy
is used as a TCP calibration. The tool CalibWare guides through the calibration process and
calculates new compensation parameters. This is detailed further in the manual xx.
If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy
calibration is required in order to establish full performance. For most cases after motor and
transmission replacements that do not include taking apart the robot structure, standard
calibration is sufficient. Standard calibration also supports wrist exchange.

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5 Calibration information
5.3. Calibration scales and correct axis position

5.3. Calibration scales and correct axis position

Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.

Calibration scales, IRB 2400


The illustration below shows the calibration scale positions on IRB 2400:

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5 Calibration information
5.3. Calibration scales and correct axis position

en0200000273

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5 Calibration information
5.4. Calibration movement directions for all axes

5.4. Calibration movement directions for all axes

Calibration movement directions


When calibrating, the axis must consistently be run towards the calibration position in the
same direction, in order to avoid position errors caused by backlash in gears etc. Positive
directions are shown in the figure below.
This is normally handled by the robot calibration software.
Note! The figure shows an IRB 7600, but the positive direction is the same for all robots,
except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!

xx0200000089

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5 Calibration information
5.5. Updating revolution counters

5.5. Updating revolution counters

General
This section details how to perform a rough calibration of each robot axis, i.e. updating the
revolution counter value for each axis, using either the TPU or the FlexPendant.

Manually running the robot to the calibration position


This procedure details the first step when updating the revolution counter; manually running
the robot to the calibration position.

Step Action Note


1. Select axis-by-axis motion mode.
2. Jog the robot so that the calibration marks lie Shown in section Calibration scales
within the tolerance zone. and correct axis position on page
186.
3. When all axes are positioned, store the Detailed in sections:
revolution counter settings. Storing the revolution counter setting
with the TPU on page 190
(RobotWare 4.0).
Storing the revolution counter setting
with the FlexPendant on page 191
(RobotWare 5.0).

Correct calibration position of axis 4 and 6


When running the robot to calibration position, it is extremely important to make sure that
axes 4 and 6 of the below mentioned robots are positioned correctly. The axes do not have
any mechanical stops and can therefore be calibrated at the wrong turn.
Make sure the axes are positioned according to the correct calibration values, not only
according to the calibration marks. The correct values are found on a label, located either on
the lower arm or underneath the flange plate on the base.
At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before
the revolution counters are updated.
If one of the below mentioned axes are rotated one or more turns from its calibration position
before updating the revolution counter, the exact calibration position will be lost due to
uneven gear ratio. This affects the following robots:

Robot variant Axis 4 Axis 6


IRB2400L (5kg) Yes No

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5 Calibration information
5.5. Updating revolution counters

Storing the revolution counter setting with the TPU


This section details the second step when updating the revolution counter; storing the
revolution counter setting with the TPU (RobotWare 4.0).

Step Action Note


1. Press the button "Miscellaneous" then ENTER to select the
service window.

xx0100000194

2. Select Calibration from the View menu.


The Calibration window appears.
If there is more than one unit connected to the robot, they will
be listed in the window.

xx0100000201

3. Select the desired unit and choose Rev Counter Update


from the Calib menu.
The Revolution Counter Update window appears.

xx0100000202

4. Select the desired axis and press Incl to include it (it will
be marked with an x) or press All to select all axes.
5. Press OK when all axes that are to be updated are marked
with an x.
CANCEL returns to the Calibration window.

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5 Calibration information
5.5. Updating revolution counters

Step Action Note


6. Press OK again to confirm and start the update.
CANCEL returns to the Revolution Counter Update window.
7. At this point, it is recommended that the revolution counter Not required.
values are saved to a diskette.
8.

Caution!
If a revolution counter is incorrectly updated, it will cause
incorrect robot positioning, which in turn may cause damage or
injury!
Check the calibration position very carefully after each update.
How to perform the check is detailed in section Checking the
calibration position on page 193.

Storing the revolution counter setting with the FlexPendant


This procedure details the second step when updating the revolution counter; storing the
revolution counter setting with the FlexPendant (RobotWare 5.0).

Step Action
1. On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.
2. Tap the mechanical unit in question.
A screen is displayed: tap Rev. Counters.

en0400000771

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5 Calibration information
5.5. Updating revolution counters

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

Caution!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 193.

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5 Calibration information
5.6. Checking the calibration position

5.6. Checking the calibration position

General
Check the calibration position before beginning any programming of the robot system. This
may be done in one of two ways:
• Using a MoveAbsJ instruction with argument zero on all axes
• Using the Jogging window on the teach pendant

Using a MoveAbsJ instruction on the TPU, S4Cplus


This section describes how to create a program, which runs all the robot axes to their zero
position

Step Action Note


1. Crate a new program
2. Use MoveAbsJ
3. Create the following program: MoveAbsJ
[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs
, v1000, z50, Tool0
4. Run the program in manual mode
5. Check that the calibration marks for the axes align The calibration marks are
correctly. If they do not, update the revolution shown in section Calibration
counters! scales and correct axis
position on page 186.
How to update the revolution
counters is detailed in section
Updating revolution counters
on page 189

Using a MoveAbsJ instruction on the FlexPendant, IRC5


This section describes how to create a program, which runs all the robot axes to their zero
position.

Step Action Note


1. On ABB menu tap Program Editor.
2. Create a new program.
3. Use MoveAbsJ in the Motion&Proc menu.
4. Create the following program: MoveAbsJ
[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOff
s, v1000, z50, Tool0
5. Run the program in manual mode.
6. Check that the calibration marks for the axes align The calibration marks are
correctly. If they do not, update the revolution shown in section Calibration
counters! scales and correct axis
position on page 186.
How to update the revolution
counters is detailed in section
Updating revolution counters
on page 189.

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5 Calibration information
5.6. Checking the calibration position

Using the Jogging window on the TPU, S4Cplus


This section describes how to jog the robot to all axes zero position.

Step Action Illustration/information


1. Open the Jogging window.

xx0100000195

2. Choose running axes-by-axes.

xx0100000196

3. Manually run the robot axes to a position where the


axis position value read on the TPU, is equal to
zero.
4. Check that the calibration marks for the axes align The calibration marks are
correctly. If they do not, update the revolution shown in section Calibration
counters! scales and correct axis
position on page 186.
Detailed in section Updating
revolution counters on page
189.

Using the Jogging window on the FlexPendant, IRC5


This section describes how to jog the robot to all axes zero position.

Step Action Note


1. Tap Jogging in the ABB menu.
2. Tap Motion mode to choose group of axes to jog.
3. Tap axes 1-3 to jog axes 1, 2 or 3.
4. Manually run the robots axes to a position where the
axis position value read on the FlexPendant, is equal
to zero.
5. Check that the calibration marks for the axes align The calibration marks are
correctly. If they do not, update the revolution shown in section Calibration
counters! scales and correct axis
position on page 186.
How to update the counters
is detailed in section
Updating revolution counters
on page 189.

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Index

C
Calibration position 189
calibration position, checking 193
calibration position, jog to 194
Connection of external safety devices 15
D
direction of axes 188
L
Limitation of Liability 16
N
negative directions, axes 188
P
positive directions, axes 188
R
Revolution counters 189
S
Safety, service 15
U
Updating revolution counters 189
V
Validity and responsibility 15

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5.6. Checking the calibration position

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