IRC5-IRB2400 Prod Man Part1 3HAC022031-001 - Reva - en - Procedures

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 ABBs 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 Vsters 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 robots 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
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.2 Refitting of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.3 Removal of the tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4 Reassemble of the tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.1 Removal of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.2 Reassemble of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.3 Removal of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.4 Reassemble of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.5 Removal of the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.6 Reassemble of the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1 Removal of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.2 Refitting of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.3 Removal of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.4 Refitting of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.5 Removal of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.6 Refitting of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.7 Removal of motor, axis 4-6;IRB 2400L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.8 Refitting of motor, axis 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.9 Removal of motor, axis 4-6, IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.10 Refitting of motor, axis 4-6 IRB 2400/10/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110 114 117 120 123 127 131 133 135 137 140 143 145 148 152 155 159 162 167 170
4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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
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
Overview
Overview
About this manual This manual contains instructions for 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. mechanical and electrical installation of the manipulator maintenance of the manipulator mechanical and electrical repair of the manipulator.
Who should read this manual? This manual is intended for: Prerequisites The reader should... be a trained maintenance/repair craftsman have the required knowledge of mechanical and electrical installation/repair/ maintenance work. installation personnel maintenance personnel repair personnel.
Organization of chapters The manual is organized in the following chapters: Chapter

Safety, service Installation and commissioning Maintenance Repair Calibration information Decommissioning
Contents
Safety information Information about installation of the manipulator. Information about maintenance work, including maintenance schedules. Information about repair work. Procedures that do not require specific calibration equipment. General information about calibration. Environmental information about the manipulator.
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. Chapter Calibration replaced with chapter Calibration information. Safety chapter rewritten.
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
8. Remove the rear attachment screws, gearbox.
Note/Illustration
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
3. Fit a new sealing, axis 2 to the gearbox.
Note/Illustration
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.
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 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 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
In addition, spare part information is supplied for the entire option.
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 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. 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
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:
10
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)
Operators manuals
How to use the application Examples of how to use the application
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: 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) Operators manual - IRC5 with FlexPendant Operators manual - RobotStudioOnline Trouble shooting Manual for the controller and robot
11
12
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.
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 manipulators arm Brake testing Risk of disabling function "Reduced speed 250 mm/s" Safe use of the Teach Pendant Unit enabling device Work inside the manipulators working range Signal lamp (optional)
14
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. Users 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.
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
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
Installation of safety devices Changing robot modes
Detailed in document
Product manual for the manipulator Users Guide
Section
Installation and commissioning Start-up Installation and commissioning
Restricting the working space Product manual for the manipulator
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.
18
1 Safety
Complete robot Safety risk

Hot components!
Description
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

Cable packs are sensitive to mechanical damage!
Description
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

Gears may be damaged if excessive force is used!
Description
Caution!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!
19
1 Safety
Balancing device Safety risk

Dangerous balancing device!
Description
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
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.
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
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.
23
1 Safety
1.2.3.5. Safety risks during operational disturbances
1.2.3.5. Safety risks during operational disturbances

General 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. 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.
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
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.
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 robots 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
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.
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
1 Safety
1.2.4.3. Emergency release of the robots arm
1.2.4.3. Emergency release of the robots arm

Description In an emergency situation, any of the robots 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!
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
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.
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
1 Safety
1.2.4.7. Work inside the manipulators working range
1.2.4.7. Work inside the manipulators working range

WARNING! If work must be carried out within the robots 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 robots 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.
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
DANGER
Signification
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, impact, fall from height etc. 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 crushing, impact, fall from height etc. The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.
danger
WARNING
warning
ELECTRICAL SHOCK
Electrical shock
CAUTION
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 warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.
34
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
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
1.
Action
Info/Illustration
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. If possible, use the hold-to-run button whenever possible. The hold-to-run button is used in manual mode, not in automatic mode. How to use the hold-to-run control in RobotWare 5.0 is detailed in section How to use the hold-to-run switch in the Operators 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 Users Guide.
2.
3.
Make sure no personnel is present within the manipulator working range before pressing the start button.
36
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
1.
Action
Use a wrist strap
Note/Illustration
Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly. The mat must be grounded through a currentlimiting resistor. The mat should provide a controlled discharge of static voltages and must be grounded.
2. 3.
Use an ESD protective floor mat. Use a dissipative table mat.
Assemble the wrist strap The picture illustrates how the ESD wrist strap is assembled in the controller cabinet.
xx0400001055
A B C
The strap is fastened to a button on the side of the control cabinet. When not used, the wrist strap is placed on the power supply unit. Power supply unit
37
1 Safety
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 lead to internal over-pressure inside the gearbox which in turn may: damage seals and gaskets completely press out seals and gaskets prevent the manipulator from moving freely. Mixing types of oil may cause severe damage to the gearbox! Make sure not to overfill the gearbox when filling with oil! After filling, check the correct oil levels as described in section .
Do not overfill!
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!
Do not mix types of oil!
38
1 Safety
Warning
Description
Warm oil drains quicker than cold oil.
Elimination / Action
When changing gearbox oil, first 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 drained from the gearbox.
Specified amount depends on drained volume!
39
1 Safety
40
2 Installation and commissioning

2.1. Introduction

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.
41

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 (operation)
2000 N 4100 1400 N - 4100 1400 N 3400 Nm 550 Nm
Forces and torques

Force xy (upright/ suspended) Force z (upright) Forze z (suspended) Torque Mxy Torque Mz
Max. load (emergency stop)

2600 N 4100 1900 N - 4100 1900 N 4000 Nm 900 Nm
42

2.2.1. Pre-installation procedure
IRB 2400 - L Endurance load (operation)

1700 N 4100 1100 N - 4100 1100 N 3000 Nm 450 Nm
Forces and torques

Force xy Force z, upright Force z, suspended Torque Mxy Torque Mz
Max. load (emergency stop)

2100 N 4100 1400 N - 4100 1400 N 3400 Nm 900 Nm
Requirements on foundation The table below shows the requirements of the foundation where the manipulator is to be fitted:
Requirement
Min. levelity Max. tilt Min. resonance frequency
Value
0.5 mm 5 30 Hz
Storage conditions The table below shows the allowed storage conditions for the manipulator:
Parameter
Max. ambient temperature, storage Min. ambient temperature, storage Max. ambient humidity, storage
Value
+55 C -25 C Max. 95% at constant temperature
Max. ambient temperature, storage (less than 24 hrs) +70 C
Operating conditions The table below shows the allowed operating conditions for the manipulator and controller:
Parameter
Max. ambient temperature Min. ambient temperature Max. ambient humidity
Value
+45 C +5 C Max. 95% at constant temperature
Protection classes The table below shows the protection class of the main parts of the robot system:
Equipment
Manipulator
Protection class
IP 67
43

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. Angle axis 3

0 0 1 -60 2 65 3 -60 4 24,5 5 -60 6 65
X
970 404 602 1577 400 -1611 -115
Z
1620 2298 745 -246 -403 623 1088
Angle axis 2
0 0 0 110 110 -100 -100
44

2400/10, 16 The working area is the same for both floor and inverted (suspended). Positions at wrist center.
xx0200000160
Pos. Angle axis 3

0 0 1 -60 2 65 3 -60 4 18,3 5 -60 6 65
X
855 360 541 1351 400 -1350 -53
Z
1455 2041 693 -118 -302 624 1036
Angle axis 2
0 0 0 110 110 -100 -100
45

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
Sling line Type: KDBK 7-8.
Note
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

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
1.
Action
Push the "brake release button" to release the holding brakes, see following illustration.
Info/Illustration
xx0200000168
A: Pushbutton
47

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
1.
Action
Connect an external power supply to connector XP1 as shown in the following illustration.
Info/Illustration
xx0200000167
2. Push the "brake release button" to release the holding brakes, see the previous illustration.
A: R1.MP B: Push button C: B8 = +24 V D: C10 = 0V
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

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: Quality Suitable washer:
M16 x 50 Quality 8.8 Thickness: 3 mm Outer diameter: 30 mm Inner diameter: 17 mm 190 Nm
Tightening torque:
Hole configuration The illustration below shows the hole configuration used when securing the manipulator:
xx0200000181
49

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
Guide sleeves
Art. no.
2151 0024-169
50

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 B -
Lifting beam Fork lift Inverted mounting tool 3HAC 8961-1
2. Seal the eight holes in the bottom plate with plastic plugs, see following illustration.
51

xx0200000215
Plastic plugs (x8)
52

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 Users Guide (RobotWare 4.0), or Operators 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.
53

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

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.
A B C
Description
Hex socket head cap screw Plain washer Removable stop axis 1
Article number
9ADA 183-65 9ADA 312-9 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 2 3
Stop axis 1. removable Plain washer Hex socket head cap screw
Mounting extra stops The section below shows how to mounting an extra mechanical stop. Step
1. 2. 3. 4. 5.
Action
Make a copy of the drilling pattern. Mark out the location of the holes on each stop. Drill the holes through, 10.2 cut threads, M12. Mount the stops without tightening the screws. Turn axis 1 manually and check the working range between the stops.
Note/Illustration
If necessary correct the angle of impact.
55

Drilling pattern for extra stops Pictures shows the drill pattern to be used when drilling for mechanical stops on axis 1.
xx0200000206
56

Drill pattern
xx0200000207
57


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
+110 / -100 +110 / -70 +110 / -40 +80 / -100 +80 / -70 +80 / -40 +50 / -100 +50 / -70 +50 / -40 +20 / -100 +20 / -70 +20 / -40
Qty. item 1
1 2 1 2 3 2 3 4 3 4 5
Qty. item 2
2 2 2 2 2 2 2 2 2 2 2
Qty. item 3
2 4 2 4 6 4 6 8 6 8 10
58

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
59

60
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.
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.
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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 activity
Oil change in wrist unit Change of back-up battery for SMB unit
Interval
After first 4,000 h, then every 60 mth.1 12,000 h2 12-36 mths 3
Note
Detailed in section:
Change of oil in wrist unit IRB 2400/10/16 / L on page 64
Measuring the Change the backup capacity of the battery on page 67 battery backup unit to the SMB Replace if required.
Inspection of all 36 mths signal cabling in lower and upper arm Replacement of 60 mths mechanical stop axis 1 Oil change in 40,000 h gearboxes, axes 1,2, 3 and 4
Replace if bent.
Replacement detailed in section .
Lubricated for life. Maintenance free 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 40C. 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.
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 B
Oil plugg Oil plugg (air inlet when draining from oil plug A)
Required equipment Spare part no.
Equipment
Standard toolkit
Art. no.
Note
The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Draining the gearbox (IRB 2400/10, /16) The procedure below details how to drain the oil from the wrist unit.
64
3 Maintenance
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
1.
Action
Run the upper arm to a horizontal position and turn axis 4 to the calibration position.
Note/Illustration
xx0300000120
2.
Remove the oil plugs in the wristNOTE! loosen the air plug for better draining. Turn axis 4 through 90 so that the oil plug on the side of the wrist is pointing downwards.
3.
xx0300000121
4. 5.
Then turn axis 4 another 90 Let the remaining oil run out through the hole on the tilt housing
65
3 Maintenance
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
1. 2.
Action
Run the upper arm to a horizontal position and turn axis 4 to the calibration position. 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 Note! If the robot is mounted in suspension, the wrist should be turned 180 Put the oil plugs back in the wrist
Note/Illustration
3. 4.
66
3 Maintenance
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 B
SMB backup battery SMB backup battery connection cable
Required equipment Equipment

Standard toolkit
Art. no.
Note
Measuring The procedure below details how to measur the SMB power backup unit
67
3 Maintenance
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
1.
Action
Remov the front cover of the robot fot.
Note/Illustration
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 coarsecalibrated after the battery change.) Loosen the battery terminals from the serial measuring board and cut the clasp that keep the battery unit in place. Install a new battery with a clasp and connect the terminals to the serial measuring board. 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. Mount the front cover of the robot fot Described in sectionReassemble of SMB related equipment on page 127
3.
4. 5.
6.
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 batterys 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
3 Maintenance
The estimated max life time in years for the different lithium batteries and the recommended exchange interval is shown below
User type:
Vacation (4 weeks) power off Weekend power off + user type 1 Weekend power off + user type 1 and 2 * Because of material ageing the maximum life time in service is 5 years.
Exchange 3cell:
every 5 years every 2 years every year
Exchange 6cell:
every 5 years* every 4 years every 2 years
Min
Ni-Cd Lithium 7.0 V 7.0 V
Max
8.7 V -
69
3 Maintenance
70
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.
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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.
Leakdown tester Leak detection spray
Art. no.
3HAC 0207-1 -
Note
Procedure Step
1. 2.
Action
Finish the refitting procedure of the motor or gear in question.
Note/Illustration
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. 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. Disconnect the compressed air supply. 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. Was any pressure drop evident? Localize the leak as detailed below. Remove the leakdown tester, and refit the oil plug. The test is complete. Spray suspected leak areas with leak detection spray Art. no. is specified above! . Bubbles indicate a leak. When the leak has been localized: take the necessary measures to correct the leak.
3.
4. 5.
6.
7.
8.
72
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.
Grease
Art. no.
3HAB 3537-1
Note
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 pretensioning 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.
73
4 Repair
4.2.3. Mounting instructions for seals

General This sections details how to mount different types of seals to the manipulator. Equipment Equipment, etc.
Grease
Art. no.
3HAB 3537-1
Note
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. Action
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). Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced, as it may result in future leakage. 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. Mount the seal correctly with a mounting tool. Never hammer directly on the seal as this may result in leakage.
Step
1.
Note
2.
3.
4.
74
4 Repair
Flange seals and static seals The procedure below details how to fit flange seals and static seals. Step
1.
Action
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. Clean the surfaces properly and in accordance with ABB ROBOTICS PRODUCTS recommendations. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Note
2. 3. 4.
O-rings The procedure below details how to fit o-rings. Step

1. 2. 3.
Action
Ensure that the correct o-ring size is used.
Note
Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings may not be used. Check the o-ring grooves. Defective o-rings The grooves must be geometrically correct and free from pores may not be used. and contamination. Lubricate the o-ring with grease. Tighten the screws evenly when assembling.
4. 5.
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 a1 a2 B C D E e F G H h
Connector at manipulator base, R1.MP, R1.SMB and R1.C/CS 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, Connectors at the serial mesurement board (SMB-unit), R2.SMB1-2 (empty), R2.G (bat), R2.FB1-3 and R2.FB4-6 Connectors at motor 2, R3.MP2 and R3.FB2 Connectors at motor 3, R3.MP3, R3.FB3,R3.LS1 and R3.LS2 Connectors at motor 1, R3.MP1, R3.FB1 Connectors at motor 4 (5 kg option), R3.MP4 and R3.FB4 Connectors at motor 4 (15 kg option), R3.MP4 and R3.FB4 Connectors at motor 5, R3.MP5 and R3.FB5 Connectors at motor 6, R3.MP6 and R3.FB6 Connectors R3.H1 and R3.H2 (5 kg option) Connectors R3.H1 and R3.H2 (15 kg option)
76
4 Repair
Equipment, etc.
Circuit Diagram
Art. no.
Note
See chapter Circuit diagram in the Product manual, reference information. The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Standard toolkit
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
Removal, cable harness, axes 1-3 The procedure below details how to remove the cable harness, axes 1-3.
77
4 Repair
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
1.
Action
Note/Illustration
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 Remove the rear cover plate (A) on the manipulator by unscrewing its attachment screws (B).
2.
xx0200000399
3. 4.
Disconnect connectors R1.MP1-3 and R2.BU1-3. Disconnect all the earth cables on the R1.M1-3 cable from the back of the cover.
78
4 Repair
Step
5.
Action
Loosen the nuts (D) holding the SMBunit 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.
Note/Illustration
xx0200000398
6.
Disconnect connector R2.FB 1-3 from the connection R2.SMB1-4 (C) on the SMB-unit .
xx0200000400
7. 8.
Unscrew the four screws securing the cable gland. Remove the adapter plate from the harness by removing its two attachment screws.
This releases the cable harness from the frame.
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
79
4 Repair
Step
Action
Note/Illustration
11. Disconnect all connectors at motor 1, 2 and motor 3,R3.Mp1-3 (A) and R3.FB13 (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 a1 a2 B
Connector at manipulator base, R1.MP, R1.SMB and R1.C/CS 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, Connectors at the serial mesurement board (SMB-unit), R2.SMB1-2 (empty), R2.G (bat), R2.FB1-3 and R2.FB4-6 Connectors at motor 2, R3.MP2 and R3.FB2
80
4 Repair
C D E e F G H h
Connectors at motor 3, R3.MP3, R3.FB3,R3.LS1 and R3.LS2 Connectors at motor 1, R3.MP1, R3.FB1 Connectors at motor 4 (5 kg option), R3.MP4 and R3.FB4 Connectors at motor 4 (15 kg option), R3.MP4 and R3.FB4 Connectors at motor 5, R3.MP5 and R3.FB5 Connectors at motor 6, R3.MP6 and R3.FB6 Connectors R3.H1 and R3.H2 (5 kg option) 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. Action Note/Illustration
Step
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 Remove the rear cover plate (A) on the manipulator by unscrewing its attachment screws (B).
2.
xx0200000399
3. 4.
Disconnect connectors R1.MP4-6 and R2.BU4-6. Disconnect all the earth cables on the R1.M4-6 cable from the back of the cover.
xx0200000403
81
4 Repair
Step
5.
Action
Loosen the nuts (D) holding the SMBunit 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.
Note/Illustration
xx0200000398
6.
Disconnect connector R2.FB 4-6 from the connection R2.SMB4-6 (B) on the SMB-unit .
xx0200000400
7. 8.
Unscrew the four screws securing the cable gland. Remove the adapter plate from the harness by removing its two attachment screws (A).
This releases the cable harness from the frame.
xx0200000404
Note! Different manipulator versions are fitted with different plate versions. Make sure the correct one is used to avoid cable failure.
82
4 Repair
Step
9.
Action
Remove the upper bracket securing the cables to the arm house by unscrewing its two attachment screws (C). Cut the strip clamp (B)
Note/Illustration
xx0200000405
10. Remove the back cover of the motors 46, 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.
83
4 Repair
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 a1 a2 B C D E e F G H h
Connector at manipulator base, R1.MP, R1.SMB and R1.C/CS 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, Connectors at the serial mesurement board (SMB-unit), R2.SMB1-2 (empty), R2.G (bat), R2.FB1-3 and R2.FB4-6 Connectors at motor 2, R3.MP2 and R3.FB2 Connectors at motor 3, R3.MP3, R3.FB3,R3.LS1 and R3.LS2 Connectors at motor 1, R3.MP1, R3.FB1 Connectors at motor 4 (5 kg option), R3.MP4 and R3.FB4 Connectors at motor 4 (15 kg option), R3.MP4 and R3.FB4 Connectors at motor 5, R3.MP5 and R3.FB5 Connectors at motor 6, R3.MP6 and R3.FB6 Connectors R3.H1 and R3.H2 (5 kg option) Connectors R3.H1 and R3.H2 (15 kg option)
84
4 Repair
Equipment, etc.
Cable unit, axes 1-3 Cable unit, axes 4-6 Cable unit, axes 4-6 Opt 043 Motor gasket for motor 1-3 Motor gasket for motor 4-6 Sealing Loctite 574 Cable straps Circuit Diagram
Spare part no.

3HAC 4791-1 3HAC 8865-1 3HAC 8520-1 3HAC 4419-1 3HAB 4429-1 3HAB 5922-1 1234 0011-116 2166 2055-3
Art. no. Note
Option 043
Flange sealing L=208mm See chapter Circuit diagram in the Product manual, reference information. The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Standard toolkit
Refitting, cable harness, axes 1-3 The procedure below details how to refit the cable harness, axes 1-3.
85
4 Repair
1.
Action
In order to facilitate refitting of the cable harness, run the manipulator to the specified position: Axis 1: 0 Axis 2: 0 Axis 3: 0 Axis 4: 0 Axis 5: +90 Axis 6: no significance Gently pull the down the cable harness through the center hole of axis 1.
Note/Illustration
Axes 2 and 3 may be tilted slightly to improve access.
2. 3. 4.
Mount the motor case on motor 1-3 using Note! Always mount a new gasket art the 3 screws no. 3HAC 4419-1 Reconnect all connectors at motor 1, 2 and 3. R3.Mp 1-3 (A) and R3.FB 1-3 (B)
xx0200000401
5. 6.
Mount the back cover of the motors 1-3 Mount the upper bracket securing the cables to the arm house, using the two attachment screws.
Use the 5 Torx screw fitted in the holes (C) in figure above.
86
4 Repair
Step
7.
Action
Mount the adapter plate to the harness by using its two attachment screws (A).
Note/Illustration
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.
87
4 Repair
Step
9.
Action
Connect connectors R2.FB 1-3 to the connection R2.SMB1-4 (C) on the SMBunit .
Note/Illustration
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.M13 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
4 Repair
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.
1.
Action
Note/Illustration
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 Gently pull the down the cable harness through the center of lower robot arm and through the hole of axis 1. Mount the motor case on motor 4-6 using the 9 torx screws Note! Always mount a new gasket art no. 3HAB 4429-1
2.
3.
89
4 Repair
Step
4.
Action
Reconnect all connectors at motor 4, 5 and 6. R3.Mp 4-6 (A) and R3.FB 13 (B) A- R3.mp5 B- R3.mp6 C- R3.mp4 D- R3.fb5 E- R3.fb6 F- R3.fb4
Note/Illustration
xx0200000406
xx0300000063
xx0300000062
90
4 Repair
Step
5. 6.
Action
Mount the back cover of the motors 4-6 Mount the upper bracket securing the cables to the arm house, using the two attachment screws. Mount the adapter plate to the harness by using its two attachment screws (A).
Note/Illustration
7.
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.
91
4 Repair
Step
9.
Action
Connect connectors R2.FB 4-6 to the connection R2.SMB4-6 (B) on the SMB-unit .
Note/Illustration
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
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 B C D E
Wrist Upper arm Lower arm Frame Fot
93
4 Repair
Required equipment Spare part Art. no. no.
Equipment, etc.
Lifting device, manipulator Special toolkit Standard toolkit
Note
Location The procedure below details how to remove the wrist from the robot upper arm.
xx0300000104
A B C
Screws Oil-plug 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
4 Repair
1. 2.
Action
Note/Illustration
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 Undo screws and remove the wrist. Shown in figure in section Location of wrist on page 93
95
4 Repair
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 B C D E
Wrist Upper arm Lower arm Frame Foot
Required equipment Spare part no. Art. no.
Equipment, etc.
Lifting device, manipulator Special toolkit Grease
Note
3HAB 3537-1
Shell Alvania WR2
96
4 Repair
Equipment, etc.
Standard toolkit
Spare part no.
Art. no.
Note
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 B C
Screws Oil-plug Wrist
NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!
97
4 Repair
Step
1. 2.
Action
Clean the surface of the tubular shaft.
Note/Illustration
Grease the O-ring with grease Shell Alvania Shown in Reassemble the new WR2, ABBs 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. 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
3.
4.
Fix the wrist with two screws and two washers. Dismantle the M8 guide pins. Mount the other two screws and washers. 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. 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
5.
6.
xx0200000425
A- Gears on drive shaft unit, axis 5-6 B- Gears on the wrist 7. 8. 9. Tighten screws (A) with washer to a torque of 17 Nm Check the play by moving axes 5 and 6 by hand Fill with oil. See the sectionChange of oil in wrist unit IRB 2400/10/16 /L on page 64 Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
10. Calibrate the robot.
98
4 Repair
4.4.3. Removal of wrist IRB 2400L

x0300000409
A B C D E
Equipment, etc.
Lifting device, manipulator Special toolkit
Art. no.
Note
99
4 Repair
Equipment, etc.
Standard toolkit
Spare part no.
Art. no.
Note
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
4 Repair
Step
1.
Action
Remove the oil plug on the wrist and drain it from all the oil.
Info/Illustration
x0300000104
2. Undo screws and remove the wrist
A : Screw B : Oil plug (air inlet) Wrist unit
101
4 Repair
4.4.4. Refitting of wrist IRB 2400L.

x0200000409
A B C D E
Equipment, etc.
Standard toolkit
Note
102
4 Repair
Equipment, etc.
Grease Lifting device, manipulator
Spare part Art. no. no.
Note
Location Step
1. 2. 3. 4. 5. 6. 7.
Action
Clean the surface of the tubular shaft Apply Loctite 574 all around. Mount the wrist, tighten screws to a torque of 8.3 Nm 10% Screw the clamping sleeves together using screws to a torque of 5.7 Nm Replace the plugs Mount the cover at the motor side of axis 5-6. Calibrate the robot!
Info/Illustration
Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
103
4 Repair
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 B C D E
Wrist axis 5-6 Upper arm axis 4-3 Lower arm axis 2 Frame axis 1 Robot foot

3HAB 9009-1 To be used together with lifting eye, M12 and lifting device, upper arm.
Equipment
Lifting device, upper arm Special tool Lifting tool (chain)
Art. no. Note/Illustration
104
4 Repair
Equipment
Standard toolkit
Spare part no.
Art. no. Note/Illustration

Tie Rod attachment
xx0200000436
A B C
Cover KM nuts 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!
105
4 Repair
Step
1.
Action
Dismount the tie rod as described in chapter Removal of the tie rod on page 117 Loosen the connectors of the motors of axes 4, 5 and 6 Disconnect the connection box from the motors. Remove the covers (Left + Right) Undo the KM nuts (Left + Right). Use sleeve 6369 901-480 Remove screws (Left + Right) Mount the lifting device to the upper arm, and lift enough for the strap to stretch without lifting the robot.
Note/Illustration
2. 3. 4. 5. 6. 7.
Detailed in Removal of motor, axis 4-6;IRB 2400L on page 159
Detailed in Tie Rod attachment on page 105 Detailed in Tie Rod attachment on page 105 Detailed in Tie Rod attachment on page 105
xx0200000435
Lifting without lifting tool! 8. Pull out the shaft. Use tool 3HAB 9009-1. Mark the shafts (left, right).
106
4 Repair
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 B C D E
Wrist axis 5-6 Upper arm axis 4-3 Lower arm axis 2 Frame axis 1 Robot foot

3HAB 9009-1 Lifting strap
Equipment
Lifting device, upper arm Special tool Lifting tool
Art. no.
Note/Illustration
107
4 Repair
Equipment
Standard toolkit
Spare part no.
Art. no.
Note/Illustration
Tie Rod attachment
xx0200000436
A B C
Cover KM nuts Screw
Reassemble The procedure below details how to reinstall the complete upper arm.
108
4 Repair
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! Action
Mount sealings in the upper arm Mount the inner ring of the bearings on shafts. Raise the upper arm into the assembly position. Install shaft spindles (both sides). Insert screws and tighten. 90 Nm 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 Mount the sync. plate for axis 3. Reconnect the connection boxes and the cabling. Calibrate the robot as specified in this chapter, Calibration in the installation manual Use tool No. 3HAB 6464-1.
Step
1. 2. 3. 4. 5. 6.
Note/Illustration
7. 8. 9.
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 B C D E
Wrist Upper arm Lower arm Frame Robot foot
110
4 Repair
Required equipment Equipment, etc.

Hoisting equipment Standard toolkit The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Spare part no. Art. no. Note
Lifting off the lower arm
xx0200000439
Removal of complete lower arm The procedure below details how to remove the complete lower arm.
111
4 Repair
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. Note/Illustration
Step Action
1. Remove the upper arm.
xx0200000435
Detailed in Removal of complete upper arm on page 104. 2. Attach the crane to the lower arm 3. Remove the tie rod. 4. Remove the parallel arm Shown in the figure in section Lifting off the lower arm on page 111 Detailed in Removal of the tie rod on page 117. 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
4 Repair
Step Action
6. Loosen all screws (A)
Note/Illustration
xx0200000440
7. Take off the lower arm
Shown in the figure in section Lifting off the lower arm on page 111
113
4 Repair
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 B C D E
Wrist Upper arm Lower arm Frame Robot foot
114
4 Repair

3HAB 3537-1
Equipment, etc.
Bearing Grease Standard toolkit
Note
For lubricating shaft hole The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Reassemble of lower arm
xx0200000441
Refitting, lower arm The procedure below details how to refit the complete lower arm.
115
4 Repair
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! Note/Illustration
Step Action
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 5. Fix the parallel arm to gearbox 3 using screws and tighten. 6. Replace the upper arm 7. Replace the cabling 8. Recalibrate the robot! Detailed in chapterReassemble of the parallel arm on page 137 68 Nm Detailed in chapterReassemble of complete upper arm on page 107 Described in chapter Refitting of cable harness on page 84 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
4 Repair
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 B
Tie rod Parallel arm
Equipment, etc.
Standard toolkit
Art. no. Note

117
4 Repair
Tie rod
xx0200000443
A B C D E F G H I
Bearing Sealing Back up ring Screw, hex. socket head cap Locking Washer Bearing Upper connection IRB 2400 5 kg Bearing Sealing Bearing Bearing Sealing Screw
Removal of tie rod The procedure below details how to remove the tie rod.
118
4 Repair
1. 2. 3. 4. 5.
Action
Remove screw (A) upper. Remove screw (A) lower. Remove Locking Washer (B) Insert a screw in the center, to be used as support. Use a crane to secure the upper arm.
Note/Illustration
Shown in Illustration Tie rod on page 118 Shown in Illustration Tie rod on page 118 Shown in Illustration Tie rod on page 118 Shown in figure in section Location of tie rod on page 117 Shown in Illustration Tie rod on page 118
6. 7.
Use a puller to pull out the tie rod Change the bearings (D) and seals
119
4 Repair
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 B
Required equipment Spare part Art. no. Note no.
Equipment, etc.
Loctite 243 Grease Standard toolkit
120
4 Repair
Tie rod
xx0200000443
A B C D E F G H I
Bearing Sealing Back up ring Screw, hex. socket head cap Locking Washer Bearing Upper connection IRB 2400 5 kg Bearing Sealing Bearing Bearing Sealing 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.
121
4 Repair
Step
1.
Action
Be sure to secure the upper arm.
Note/Illustration
Use a crane! Shown in figure section Location of tie rod on page 120 Shown in section Tie rod on page 121 Use special tool 3HAB 6324-1. Shown in section Tie rod on page 121 Use special tool 3HAB 6324-1. Use special tool 3HAB 6331-1. Shown in section Tie rod on page 121 Shown in section Tie rod on page 121 Shown in section Tie rod on page 121 Secure with Loctite 243
2. 3. 4. 5. 6. 7.
Fit the new bearings in the tie rod (D). Fit a new shaft sealing (E). Refit the tie rod.. Refit the back up ring Refit the Locking Washer Refit all screws.
122
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 B C D
Cable to back up battery Back up battery Serial Measurement Board Lock Nuts
123
4 Repair
Required equipment Spare part. no.
Equipment, etc.
Gasket SMB- unit Battery unit Standard toolkit
Art. no.
3HAB 5537-1 3HAB 8413-01 4944 026-4
Note
The contents are defined in section Standard toolkit in the Product manual, reference information! See chapter Circuit diagram in the Product manual, reference information. These procedures include references to the tools required.
Circuit Diagram
Cover robot foot
xx0200000399
A B
Cover plate Screw
Removal, cover on robot foot The procedure below details how to remove the cover on the robot foot
124
4 Repair
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. Action
Remove the Screws to the cover
Step
1.
Note/Illustration
Shown in the illustration Cover robot foot on page 124 NOTE! Always change every removed gasket .
2.
Remove the cover gasket art. no. 3HAB 5537-1
Removal, battery The procedure below details how to remove the SMB battery. Step
1.
Action
Remove the SMB battery cover by unscrewing its attachment screws . Disconnect the battery from the cable, battery/SMB board . Remove the SMB battery.
Note/Illustration
Shown in figure in section Location of SMB board on page 123
2. 3.
125
4 Repair
SMB unit
xx0200000452
A B C D E
R2.SMB1-2 (External axis) R2.SMB1-3 R2.SMB4-6 Back up battery (R2.G) 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. Note/Illustration
Detailed above in Removal, battery on page 125.
Step Action
1. Remove the SMB battery. 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
4 Repair
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 B C D
Cable to back up battery Back up battery Serial Measurement Board Lock Nuts
127
4 Repair
Required equipment Spare Art. no. part. no.

3HAB 5537-1 3HAB 8413-01 4944 026-4 The contents are defined in section Standard toolkit in the Product manual, reference information! See chapter Circuit diagram in the Product manual, reference information. These procedures include references to the tools required.
Equipment, etc.
Gasket SMB- unit Battery unit Standard toolkit
Note
Circuit Diagram
SMB unit
xx0200000452
A B C D E
R1.SMB1-2 R1.SMB1-3 R1.SMB4-6 R2.G R2:SMB
128
4 Repair
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 attachment lock nuts. Pull the battery cable through the hole in the SMB cover. Shown in figure in section Location of SMB board on page 127
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
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 attachment screws. Shown in figure in section Location of SMB board on page 127
Note/Illustration
Cover robot foot
xx0200000399
A B
Cover Screws
Reassemble of, cover on robot foot The procedure below details how to reassemble the cover on the robot foot
129
4 Repair
Step
1.
Action
Reassemble the cover gasket .
Note/Illustration
NOTE! Always change every removed gasket . Art.no. 3HAB 5537-1 Shown in the illustration Cover robot foot
2.
Reassemble the Screws holding the cover
130
4 Repair
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
Brake release
Required equipment Spare Art. no. Note part no.

Equipment, etc.
Standard toolkit
Removal of brake release unit The procedure below details how to remove the brake release circuit, located at the rear of the base.
131
4 Repair
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
1. Remove the cover at the rear of the base. 2. Unscrew the six attachment screws to the brake release circuit on the outside of the base. 3. Disconnect the cable from the brake release circuit and remove the circuit from the base. Shown in section Location and description of brake release unit on page 131
Note/Illustration
132
4 Repair
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
Brake release unit, axis 1-6
Required equipment Spare Art. part no. no.
Equipment, etc.
Standard toolkit
Note
Removal of brake release unit The procedure below details how to reassemble the brake release circuit, located at the rear of the base.
133
4 Repair
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. Note/Illustration
Step Action
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 circuit on the outside of the base. 3. Reassemble the cover at the rear of the base. Shown in section Required equipment on page 133
134
4 Repair
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 B
Required equipment Spare part no. Art. Note no.

Equipment, etc.
Standard toolkit
Special toolkit Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Removal parallel arm The procedure below details how to remove the parallel arm.
135
4 Repair
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. Action
Loosen the tie rod Remove the parallel arm
Step
1. 2.
Note/Illustration
Described in chapterRemoval of the tie rod on page 117
136
4 Repair
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 B
Required equipment Spare Art. no. part no.

3HAB 5515-1 3HAB 3537-1
Equipment, etc.
Groove ball bearing Sealing V-ring Bearing grease Standard toolkit
Note
3HAB 3643-12 61822-2RS1 Acetal (POM) 1g The contents are defined in section Standard toolkit in the Product manual, reference information!
137
4 Repair
Equipment, etc.
Special toolkit Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Spare Art. no. part no.
Note
These procedures include references to the tools required.
Assembly The procedure below details how to assemble the sealing, bearing and how do mount parallel arm on the robot.
xx0200000450
A B C D
Parallel arm Sealing V- ring Groove ball bearing Screw (hex.socket head cap )
NOTE! Please observe the following when refitting components:

138
Carefully clean the connecting surfaces. Ensure that there are no damaged surfaces or other parts that need rectifying or replacing. Replace all gaskets.
4 Repair
Step Action
1. Mount V-ring (B) on the parallel arm (A) 2. Fit a new bearing to the parallel arm. 3. Mount the other V-ring (B) on the parallel arm (A) 4. Replace the screws and tighten. 5. Mount the tie rod.
Note/Illustration
NOTE! Heat up the bearing to 170 C before mounting it on the parallel arm.
Torque of 72 Nm. Described in chapterReassemble of the tie rod on page 120
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 B C D E
Cover Connection box Screw + Spring washer Motor axis 1 Position mark
140
4 Repair
Equipment, etc.
Standard toolkit
Note
Other tools and procedures may be required. See references to these procedures in the step-bystep 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
3. Remove the Connection box by unscrewing its three attachment screws and plain washers.
A: R3.MP1 B: R3.FB1 C: Connection box
141
4 Repair
Step Action
4. Use a marker pen to mark out the position of the motor 5. Remove the motor by unscrewing its four attachment screws and plain washers.
Note/Illustration
Shown in figure in sectionLocation of motor axis 1 on page 140
6. Remove the motor by gently lifting it Shown in figure in section Location of motor straight up. axis 1 on page 140
142
4 Repair
4.7.2. Refitting of motor, axis 1

xx0200000465
A B C D E F
Cover Connection box Screws Motor axis 1 Marking O-ring
143
4 Repair
Equipment, etc.
Standard toolkit
Note
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below. Gasket O-ring Circuit Diagram 3HAB 3676-1 3HAB 3772-1
Removal The procedure below details how to refit motor, axis 1. Step Action
1. Check that the assembly surfaces are clean and the motor unscratched 2. Mount the O-ring 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 Always mount a new one, see art. no. in section Location of motor axis 1 on page 143
Note/Illustration
5. Refit the Connection box by assemble the three attachment screws and plain washers. 6. Reconnect connectors R3.MP1 and R3.FB1
xx0200000406
7. Refit the cover of the connection box
144
4 Repair

xx0200000470
A B C D E F G
Torx screw Cover Connection box Gasket Motor 2 Screw O-ring
145
4 Repair
Equipment, etc.
Standard toolkit
Note
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
4 Repair
Step Action
1. Remove the cover of the connection box 2. Loosen connectors R3.MP2 and R3.FB2
Note/Illustration
Shown in figure in section Location of motor axis 2 on page 145
xx0200000401
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 motor 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 straight out. Shown in figure in section Location of motor axis 2 on page 145
147
4 Repair

xx0200000470
A B C D E F G
148
4 Repair
Equipment, etc.
Standard toolkit
Art. no.
Note
See chapter Circuit diagram in the Product manual, reference information. 3HAB 7887-1
Mounting tool
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
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
Note/Illustration
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.
149
4 Repair
Step Action
6. Fit the tool at the rear of the motor. 7. Turn the motor shaft a couple of turns, with help of the tool.
Note/Illustration
See figure below. Tool No. 3HAB 7887-1 at See figure below.
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
10. Pull gently in one direction. Note the reading. (The gear must not turn.)
A: Mount tool No. 3HAB 7887-1
See figure above.
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>. 13. Fill with oil. 14. Refit the Connection box by assembling the three attachment screws and plain washers. 23 Nm
150
4 Repair
Step Action
15. Reconnect connectors R3.MP2 and R3.FB2.
Note/Illustration
xx0200000401
16. Refit the cover of the connection box. 17. Calibrate the robot.
Shown in figure in sectionLocation of motor axis 2 on page 148 Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
151
4 Repair

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 B C D E F G
Torxs screw Cover Connection box Gasket Motor 2 Screw O-ring
152
4 Repair
Equipment, etc.
Standard toolkit
Note
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
153
4 Repair
Step Action
4. Use a marker pen to mark out the position of the motor 5. Secure the upper arm before loosening any of the screws on the motor.
Note/Illustration
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
4 Repair

xx0200000471
A B C D E F G
155
4 Repair
Equipment, etc.
Standard toolkit
Note
See chapter Circuit diagram in the Product manual, reference information. 3HAB 7887-1
Mounting tool
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. Note/Illustration
Step Action
1. Check that the assembly surfaces are clean and the motor unscratched. 2. Mount the O-ring. 3. Install the motor, by gently lifting it straight on.
Always mount a new one, see art. no. in section Required equipment on page 156
156
4 Repair
Step Action
4. Tighten the four screws using a torque of 2 Nm.
Note/Illustration
Note the position of the motor! Use the 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, with help of the tool. See figure below.
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
10. Pull gently in one direction. Note the reading. (The gear must not turn.)
A: Mount tool No. 3HAB 7887-1
See figure abowe
1 1. 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. 13. Fill with oil. 14. Refit the Connection box by assembling the three attachment screws and plain washers. 23 Nm See the chapter, Section Oil Change in Gearboxes in maintenance manual
157
4 Repair
Step Action
15. Reconnect connectors R3.MP3 and R3.FB3.
Note/Illustration
xx0200000401
16. Refitt the cover of the connection box. 17. Calibrate the robot.
Shown in figure in sectionRefitting of motor, axis 1 on page 143 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
4 Repair
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 B C D E F G H
Torx screw Cover Connection box Screw Motor 6 Motor 5 Motor 4 Gearbox
Equipment, etc.
Standard toolkit
ote
159
4 Repair
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. Note/Illustration
Shown in figure in section Location of motor axis 4-6 on page 159
Step Action
1. Remove the cover of the connection box 2. Loosen connectors R3.MP5-6 and R3.FB5-6
xx0300000063
160
4 Repair
Step Action
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.
Note/Illustration
Shown in figure in section Location of motor axis 4-6 on page 159
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
1.
Action
Remove the cover of the connection box.
Note/Illustration
xx0200000401
2. 3.
A: R3.MP4 B: R3.FB4 C: Case
Loosen connectors R3.MP4 and Shown in figure above. R3.FB4. Remove the Connection box by unscrewing its three attachment screws and plain washers. Use a marker pen to mark out the position of the motors. 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. Remove the motors by gently lifting them straight up (horizontal movement).
4. 5.
6.
161
4 Repair
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 B C D E F G H

3HAB 3772-1 3HAB 7116-1 3HAB 3537-1 3HAB 7887-1 1171 2016-604 The contents are defined in section Standard toolkit in the Product manual, reference information!
Equipment, etc.
O-ring Loctite 243 Bearing grease Mount tool Lubricating oil Standard toolkit
Note
3 pcs
162
4 Repair
Equipment, etc.
Spare Art. no. part no.
Note
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
1. 2. 3. Check that the assembly surfaces are clean and the motor unscratched Mount a new O-ring on the motor. 3HAB 3772-1 Grease the gear with bearing grease 3HAB 3537-1
Note/Illustration
163
4 Repair
Step Action
4. Mount the tool at the rear of the motor.
Note/Illustration
xx0300000005
5. The motors 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 Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP4 connectors 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. 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!
A: Tool no. 3HAB 7887-1
6.
7.
8.
9.
Tighten the motor attachment 4.1 Nm screws and secure them with locking Loctite 243 fluid. 30ml Described in Refitting of cable harness on page 84. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
10. Fill with oil. 11. Connect the cabling. 12. Calibrate the robot.
164
4 Repair
Reassemble of motor axis 5 The procedure below details how to reassemble motor, axis 5. Step
1. 2. 3.
Action
Check that the assembly surfaces are clean and the motor unscratched Fit a new O-ring on the motor. Fit the tool at the rear of the motor.
Note/Illustration
3HAB 3772-1 Look at the figure in section Reassemble of motor axis 4 on page 163 Tool no. 3HAB7887-1.
4.
The motors 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 Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP5 connectors 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. 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! Tighten the motor attachment screws and secure them with locking fluid. Connect the cabling. 4.1 Nm Loctite 243 Described in Refitting of cable harness on page 84. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
5. 6.
7.
8. 9.
10. Calibrate the robot
1. 2.
Action
Check that the assembly surfaces are clean and the motor unscratched Fit an new O-ring on the motor.
Note/Illustration
3HAB 3772-1
165
4 Repair
Step
3.
Action
Fit the tool at the rear of the motor.
Note/Illustration
Look at the figure in section Reassemble of motor axis 4 on page 163. Tool no. 3HAB7887-1.
4.
The motors 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 Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP6 connectors 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 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! Tighten the motor attachment screws and secure them with locking fluid. Connect the cabling. 4.1 Nm. Loctite 243 Described in Refitting of cable harness on page 84 Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
5. 6.
7.
8. 9.
10. Calibrate the robot
166
4 Repair
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 B C D E F G H
Equipment, etc.
Standard toolkit
Art. no.
Note
Removal, motor axis 4-6 (10/16 kg) The procedure below details how to remove motor, axis 4-6.
167
4 Repair
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! Step
1. 2.
Before removing, clean the work area and the components to be removed. Place the removed components in a clean container. Action
Remove the cover of the connection box Loosen connectors R3.MP4-6 and R3.FB4-6
Info/Illustration
Shown in figure in section xx.
xx0200000406
3. Remove the Connection box by unscrewing its three attachment screws and plain washers. Use a marker pen to mark out the position of the motors
A: R3.MP5 B: R3.MP6 C: R3.MP4 D: R3.FB5 E: R3.FB6 F: R3.FB4
4.
168
4 Repair
Step
5.
Action
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. Remove the motors by gently lifting them straight out (horizontal movement).
Info/Illustration
6.
169
4 Repair
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 B C D E F G H
Equipment, etc.
O-ring Loctite 243 Bearing grease Mount tool Lubricating oil Standard toolkit
Art. no.
3HAB 3772-1 3HAB 7116-1 3HAB 3537-1 3HAB 7887-1 1171 2016-604
Note
The contents are defined in section Standard toolkit in the Product manual, reference information!
170
4 Repair
Equipment, etc.
Other tools and procedures may be required. See references to these procedures 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
Spare part no.
Art. no.
Note
3HAC 6670-3
1. 2. 3. 4.
Action
Check that the assembly surfaces are clean and the motor unscratched Fit a new O-ring on the motor. Grease the gear with bearing grease Fit the tool at the rear of the motor.
Info/Illustration
3HAB 3772-1 3HAB 3537-1
xx0300000005
Tool no. 3HAB 7887-1 5. The motors 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 Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP4 connectors
6.
171
4 Repair
Step
7.
Action
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. 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! Tighten the motor attachment screws and secure them with locking fluid.
Info/Illustration
8.
9.
4.1 Nm. Loctite 243 1.5 litres (0.4 US gallon) Described in Refitting of cable harness on page 84
10. Fill the gearbox whith the proper quantity of oil 11. Connect the cabling.
1. 2. 3. 4.
Action
Check that the assembly surfaces are clean and the motor unscratched Fit a new O-ring on the motor. Mount the tool at the rear of the motor. The motors 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 Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP5 connectors 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. 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! Tighten the motor attachment screws and secure them with locking fluid. Connect the cabling.
Note/Illustration
3HAB 3772-1 Tool no. 3HAB7887-1
5. 6.
7.
8. 9.
4.1 Nm. Loctite 243 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
Step
1. 2. 3. 4.
Action
Check that the assembly surfaces are clean and the motor unstructured. Fit a new O-ring on the motor. Fit the tool at the rear of the motor. The motors 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 Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP6 connectors 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 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! Tighten the motor attachment screws and secure them with locking fluid. Fill the gearbox with the proper quantity of oil
Note/Illustration
3HAB 3772-1 Tool no. 3HAB 7887-1.
5. 6.
7.
8. 9.
4.1 Nm. Loctite 243 0.8 litres (0.2 US gallon) total for 5 and 6. Described in Refitting of cable harness on page 84. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
10. Connect the cabling. 11. Calibrate the robot.
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 B
M12x50 8.8 hexagon socket head cap screw Cover
Equipment, etc.
Standard toolkit
Note
174
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. Note/Illustration
Detailed in Removal of complete lower arm on page 110. Detailed inRemoval of motor, axis 1 on page 140. Detailed in Removal of motor, axis 2 on page 145. Detailed in Removal of motor, axis 3 on page 152.
Step Action
1. Remove the complete lower arm. 2. Remove the motor, axis 1. 3. Remove the motor, axis 2. 4. Remove the motor, axis 3. 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
175
4 Repair
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 B
M12x50 8.8 hexagon socket head cap screw Cover
Required equipment Spare Art. Note part no. no.

Equipment, etc.
Standard toolkit
176
4 Repair
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: Step

1. 2.
Carefully clean the connecting surfaces. Ensure that there are no damaged surfaces or other parts that need rectifying or replacing. Replace all gaskets. Action
Fit and secure the 12 screws complete with washers . Place the gearbox upside-down on a table or similar surface and refit the bottom plate Refit the motor, axis 1. Refit the motor, axis 2. Refit the motor, axis 3. Refit the complete lower arm. Calibrate the robot. Detailed in Refitting of motor, axis 1 on page 143. Detailed in Refitting of motor, axis 2 on page 148. Detailed in Refitting of motor, axis 3 on page 155. Detailed in Refitting of complete lower arm on page 114. Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
Note/Illustration
54 Nm.
3. 4. 5. 6. 7.
177
4 Repair
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
Equipment, etc.
Standard toolkit
Note
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
4 Repair
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. Note/Illustration
Described in section Removal of wrist IRB 2400/10/16. on page 93.
Step Action
1. Dismantle the wrist
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
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 motors and remove both motors. 7. Undo the screws and remove the motor plate. 8. Remove the gear belts.
A: Screws B: Motor screws
Described in section Removal of motor, axis 4-6;IRB 2400L on page 159.
179
4 Repair
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
Equipment, etc.
Lifting device, manipulator Standard toolkit
Note
The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required. 3HAA 2393-1 3HAA 7601-050 2 pcs
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below. New timing belt Mounting Tool
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
4 Repair
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/Illustration
N.B. Do not forget the nuts on the motors!
Step Action
1. Install the belts. 2. Fit the plate using screws and washers. 3. Fit the motors. 4. Push the motors sideways to tighten the belts, using the tool. Place the round post of the tool into the motor 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 tubular shaft. 7. Tighten screws.
Tool no. 3HAA 7601-050. Tighten screws B (shown in the illustration below) to 4.1 Nm.
Do not forget the rubber damper.
xx0300000021
8. Install the cabling and mount the cover to motors axes 5 and 6. 9. Mount the wrist. 1 0 . Calibrate the robot.
A: 8.3 Nm
Detailed in Refitting of motor, axis 4-6 on page 162 Described in sectionRefitting of wrist IRB 2400/10/16 on page 96 Calibration is detailed in separate calibration manuals. Art. no. for the manuals are specified in section Document references in the Product manual, reference information.
181
4 Repair
182
5 Calibration information
5.1. Introduction
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.
183
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 calibration
Standard calibration
Description
The calibrated robot is positioned at home position, i.e. the axes positions (angles) are set to 0. Standard calibration data is found in the file calib.cfg, supplied with the robot at delivery. 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.
Calibration method
Calibration Pendulum (standard method) or Levelmeter calibration (alternative method)
Absolute Accuracy calibration (optional)
Based on standard calibration, but besides CalibWare positioning the robot at home position, the 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 absacccompensation 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
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.
185
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:
186
en0200000273
187
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
188
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
1. 2.
Action
Select axis-by-axis motion mode.
Note
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. When all axes are positioned, store the revolution counter settings. Detailed in sections: 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).
3.
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
IRB2400L (5kg)
Axis 4
Yes
Axis 6
No
189
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
1.
Action
Press the button "Miscellaneous" then ENTER to select the service window.
Note
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. 5.
Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes. Press OK when all axes that are to be updated are marked with an x. CANCEL returns to the Calibration window.
190
Step
6. 7. 8.
Action
Press OK again to confirm and start the update. CANCEL returns to the Revolution Counter Update window. At this point, it is recommended that the revolution counter values are saved to a diskette.
Note
Not required.
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
1.
Action
On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status. Tap the mechanical unit in question. A screen is displayed: tap Rev. Counters.
2.
en0400000771
191
Step
3.
Action
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. 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. 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.
4.
5.
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.
192
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
1. 2. 3.
Action
Crate a new program Use MoveAbsJ Create the following program: MoveAbsJ [[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs , v1000, z50, Tool0 Run the program in manual mode Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!
Note
4. 5.
The calibration marks are shown in section Calibration 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
1. 2. 3. 4.
Action
On ABB menu tap Program Editor. Create a new program. Use MoveAbsJ in the Motion&Proc menu. Create the following program: MoveAbsJ [[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOff s, v1000, z50, Tool0 Run the program in manual mode. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!
Note
5. 6.
The calibration marks are shown in section Calibration scales and correct axis position on page 186. How to update the revolution counters is detailed in section Updating revolution counters on page 189.
193
Using the Jogging window on the TPU, S4Cplus This section describes how to jog the robot to all axes zero position. Step
1.
Action
Open the Jogging window.
Illustration/information
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. 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.
4.
Using the Jogging window on the FlexPendant, IRC5 This section describes how to jog the robot to all axes zero position. Step
1. 2. 3. 4.
Action
Tap Jogging in the ABB menu. Tap Motion mode to choose group of axes to jog. Tap axes 1-3 to jog axes 1, 2 or 3. Manually run the robots axes to a position where the axis position value read on the FlexPendant, is equal to zero. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!
Note
5.
The calibration marks are shown in section Calibration scales and correct axis position on page 186. How to update the counters is detailed in section Updating revolution counters on page 189.
194
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
195
196

IRC5-IRB2400 Prod Man Part1 3HAC022031-001 - Reva - en - Procedures

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Product manual (part 1 of 2), procedures

2.2.1 Pre-installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 2.2.2 Working range, IRB 2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3HAC 022031-001 Revision: A

3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.3.1 Removal of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 4.3.2 Refitting of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

3HAC 022031-001 Revision: A

3HAC 022031-001 Revision: A

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

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References Reference Document Id

Revisions Revision Description

3HAC 022031-001 Revision: A

How to read the product manual

How to read the product manual

3HAC 022031-001 Revision: A

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

In addition, spare part information is supplied for the entire option.

3HAC 022031-001 Revision: A

Product documentation, M2004

Product documentation, M2004

Product documentation, M2004

How to use the application Examples of how to use the application

3HAC 022031-001 Revision: A

Product documentation, M2004

3HAC 022031-001 Revision: A

3HAC 022031-001 Revision: A

1.2 General safety information 1.2.1. Introduction

3HAC 022031-001 Revision: A

1.2.2. General information 1.2.2.1. Safety, service

3HAC 022031-001 Revision: A

1.2.2.2. Limitation of Liability

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1.2.2.3. Related information

Restricting the working space Product manual for the manipulator

3HAC 022031-001 Revision: A

3HAC 022031-001 Revision: A

Complete robot Safety risk

Cabling Safety risk

Gearboxes and motors Safety risk

3HAC 022031-001 Revision: A

Balancing device Safety risk

3HAC 022031-001 Revision: A

1.2.3.2. Safety risks related to gripper

3HAC 022031-001 Revision: A

1.2.3.3. Safety risks related to tools/workpieces

3HAC 022031-001 Revision: A

1.2.3.4. Safety risks related to pneumatic/hydraulic systems

3HAC 022031-001 Revision: A

1.2.3.5. Safety risks during operational disturbances

3HAC 022031-001 Revision: A

1.2.3.6. Safety risks during installation and service

3HAC 022031-001 Revision: A

1.2.3.7. Risks associated with live electric parts

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1.2.4. Safety actions 1.2.4.1. Safety fence dimensions

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1.2.4.2. Fire extinguishing

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1.2.4.3. Emergency release of the robots arm