Product Manual (Part 2 of 2), Reference Information: Articulated Robot

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

Product manual (part 2 of 2), reference information

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Reference information
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 Standard toolkit, IRB 2400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Part list
21
3 Foldouts
23
4 Circuit diagram
25
3HAC 022031-001 Revision: A
Overview
Overview
About this manual
This manual contains reference information for all procedures described in the Product
manual, procedures .
Usage
This manual should be used during
installation
maintenance work
repair work.
Who should read this manual?

This manual is intended for:
installation personnel
maintenance personnel
repair personnel.
Prerequisites
The reader should...
be a trained maintenance/repair craftsman
have the required knowledge of mechanical and electrical installation/repair/

maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter
Contents
Reference information
Useful information when performing installation, maintenance or

repair work (lists of necessary tools, reference documents, safety
standards).
Part list
Complete list of manipulator parts, shown in the exploded views or

foldouts.
Exploded views /
Foldouts
Detailed illustrations of the manipulator with reference numbers to

the part list.
Circuit Diagram
Circuit Diagram of the manipulator.
References
Reference
Document Id
Overview
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.
Section Document references is completed with article numbers for calibration

manuals.
Product documentation, M2000/M2000A
Product documentation, M2000/M2000A

General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
Safety information
Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)
Maintenance (descriptions of all required preventive maintenance procedures

including intervals)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual
Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
Installation information
Repair information
Maintenance information
In addition, spare part information is supplied for the entire option.
Product documentation, M2004

General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
is divided into two parts:
Product manual, procedures
Safety information
Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)
Maintenance (descriptions of all required preventive maintenance procedures

including intervals)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
RAPID Overview: An overview of the RAPID programming language.
RAPID reference manual part 1: Description of all RAPID instructions.
RAPID reference manual part 2: Description of all RAPID functions and data types.
Technical reference manual - System parameters: Description of system

parameters and configuration workflows.
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
The purpose of the application (what it does and when it is useful)
What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
How to use the application
Examples of how to use the application
Operators manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
Operators manual - IRC5 with FlexPendant
Operators manual - RobotStudioOnline
Trouble shooting Manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
Robot fundamentals (describing the fundamental aspects, functions, concept and

similar, of a robot system to provide a basic understanding of the robot system)
1.1. Introduction
1.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.
1.2. Applicable Safety Standards
1.2. Applicable Safety Standards

Standards, general
The robot is designed in accordance with the requirements of:
ISO10218, Jan. 1992, Industrial Robot Safety
ANSI/RIA 15.06-1999
ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing

systems - Basic requirements
DIN 19258 - Interbus-S, International Standard
Standards, safety fence

The following standards are applicable to the safety fence surrounding the robot cell:
ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing

systems - Basic requirements
prEN 999:1995
Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:
10
IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached
by the upper limbs.
EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human
body.
EN 811 Safety of machinery - Safety distance to prevent danger zones being reached
by the lower limbs.
Pr EN 999 Safety of machinery - The positioning of protective equipment in respect

of approach speeds of the human body.
EN 1088 Safety of machinery - Interlocking device associated with guards principles

for design and selection.
1.3. Unit conversion
1.3. Unit conversion

Converter table
Use the table below to convert units used in this manual.
Quantity
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
39.37 in
14.5 psi
11
1.4. Screw joints
1.4. Screw joints

General
This section details how to tighten the various types of screw joints on the robot and the
controller.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws
Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After
this the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated in other ways
Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
Lubricant
Art. no.
Molycote 1000 (molybdenum disulphide grease)
1171 2016-618
Tightening torque
Before tightening any screw, note the following:
12
Determine whether a standard tightening torque or special torque is to be applied. The

standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
Use the correct tightening torque for each type of screw joint.
1.4. Screw joints
Only use correctly calibrated torque keys.
Always tighten the joint by hand, and never use pneumatical tools.
Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Dimension
Tightening torque (Nm)

Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Dimension
Tightening torque
(Nm)
Class 8.8, oillubricated
Tightening torque
(Nm)
Tightening torque
(Nm)
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.
Dimension

Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8
28
34
M10
55
66
M12
96
115
M16
235
280
13
1.4. Screw joints
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
14
Dimension
Tightening torque
Nm - Nominal
Tightening torque
Nm - Min.
Tightening torque
Nm - Max.
1/8
12
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
1.5. Weight specifications
1.5. Weight specifications

Definition
In all repair and maintenance procedures, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for
each manipulator model.
Example
Below is an example of how a weight specification is presented:
CAUTION!
Caution!
The motor weighs 32 kg! All lifting equipment used must be sized accordingly!
15
1.6. Document references

General
The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced
documentation.
Product specification, robot
The product specification includes generic technical data. The specification listed below is
the English version.
Document name
Document ID
Product specification
3HAC 9112-1
Product manuals, controller

The product manuals include information about installation and service activities. The table
below specifies the article numbers of the product manuals for all controller models. The part
number -001 is the English version.
Document name
Document ID
Product manual, S4Cplus M2000
3HAC 021333-001
Product manual, S4Cplus M2000A
3HAC 021128-001
Product manual, IRC5 M2004
3HAC 021313-001
Operators manual
The operators manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operators manuals for different robot systems.
Document name
Document ID
Note
Users guide (S4Cplus)
3HAC 7793-1
Contains instructions for daily operation

of S4Cplus based robot systems.
Operators manual (IRC5)
3HAC 16590-1
Calibration manuals
16
Document name
Document ID
Note
Calibration Pendulum
Instruction
3HAC 16578-1
Enclosed with the Calibration

Pendulum Toolkit.
Instructions for Levelmeter

calibration (alternative method)
3HAC 022907-001
Enclosed with the Levelmeter 2000.
CalibWare 2.0 Users Guide
3HAC 16090-1
Calibration tool for Absolute

Accuracy calibration.
Additional documentaion
Document name
Document ID
External axes
3HAC 9299-1
Note
17
1.7. Standard toolkit, IRB 2400
1.7. Standard toolkit, IRB 2400

General
All service (repair, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. All special tools, i.e. all tools that are not considered
standard as defined below, are listed in their instructions respectively.
This way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents
Qty Tool
18
Ring-open-end spanner 8-19mm
Socket head cap 2,5-17mm
Torx socket no:20-60
Torque wrench 10-100Nm
Small screwdriver
Ratchet head for torque wrench 1/2
Socket head cap no:5, socket 1/2"" bit L 20mm
Small cutting plier
1.8. Lifting equipment and lifting instructions

General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in the
instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
19
20
2: Part list
2.0.1 Introduction
Definitions
This chapter is an appendix to the manual and contains part lists for the manipulator. The item
numbers refers to chapter Foldouts on page 35.
The part list for the manipulator sometimes differ between robot versions.
21
2.0.2 Foot
Item number refers to item number on the foldouts.Customer
Foot
cable
Itm
Qty
Name
Art. No.
Remarks
Foot
3HAC 5945-1
Gear box axes 1-3
3HAC 4795-1
12
Hex socket head cap screw
3HAB 3402-69
12
Plain washer
9ADA 312-9
Motor axes 1 and 3
3HAC 4789-1
Motor axes 1 and 3
3HAC 021346-001 5/10/16/kg, Yaskawa
M12x50 8.8 Gleitmo 610

Gleitmo 610
Motor axes 1
3HAC 021961-001 Wall ,Yaskawa
O-ring
2152 2012-434
109.5x3
12
Spring washer
2154 2033-9
8.4x18x2
3HAB 3409-45
3HAB 3409-37
Axis 4Lower
Itm
arm
Qty
Name
Customer cable extension, axis 4 3HAC 8869-1
2400L/10, /16Upper
Itm
22
13x24x2.5
Art. No.
Remarks
Option 043
See below
Arm IRB 2400/10/16
Qty
Name
Art. no.
Remark
Lower arm
3HAC 4796-1
2400/10, /16
Lower arm
3HAC 4797-1
2400L
11
Spring washer
2154 2033-10
10.5x23x2.5
12
12
3HAB 3409-50
M10x40 12.9
13
Spring tension plate
3HAC 2205-1
66x116x3
14
Damper, standard axis 2
3HAC 2180-1
15
Damper axis 3
3HAB 5512-1
16
Torx pan head roll. screw
9ADA 629-56
M6x16
17
3HAB 3409-57
M10x60 12.9
Itm
Qty
Name
Art. no.
18
Parallel arm
3HAB 9394-1
19
Sealing ring
3HAB 3732-13
V-110-L 99x10.5
20
Groove ball bearing
3HAB 3643-12
61822-2RS1
21
Sealing ring
3HAB 5515-1
Acetal
26
9ADA 183-34
M8x12
32
Sealing
3HAC 10089-2
33
Locking washer
3HAB 5523-1
SS 1914-04
34
Hex socket counters, head
2121 2852-449
M8x16 8.8
35
Sealing
3HAC 10088-4
Acetal (POM)
36
Motor axis 2
3HAC 4790-1
Motor axis 2
3HAC 021350-001 5/10/16/kg, Yaskawa
41
Lubricating oil
1171 2016-604
14 700 ml
42
Bearing grease
3HAB 3537-1
1g
1 ml Loctite 243
43
Remark
Locking liquid
3HAB 7116-1
46
Stop axis 1
3HAB 6687-1
48
Washer
2151 2082-150
49
Friction washer
3HAC 0447-1
50
Sync. mark. axis 2
3HAB 5522-1
51
Upper arm axes 4-6
54
Lock nut
2126 2851-107
M35x1.5
55
Shaft end
3HAB 5527-1
SS 1672-08
56
3HAB 7700-71
M12x60 12.9
57
VK-cover
3HAA 2166-15
VK 62x8
60
Sync. market axis 3
3HAB 8385-1
62
Washer
3HAA 1001-134
63
Torx pan head roll screw
9ADA 629-43
100
Cable unit axes 1-3
3HAC 4791-1
102
Bottom plate
3HAC 2828-1
103
Gasket
3HAC 4554-1
104
Cover
3HAC 9368-1
Standard
104
Cover
3HAC 9362-1
Foundry
104
Cover
3HAC 7242-1
Wire feeder
105
Gasket
3HAC 3200-1
106
Sealing
3HAC 4113-1
107
Bracket
3HAB 5923-1
108
Holder for cable guide
3HAB 3299-1
109
Cable guide
3HAB 5924-1
110
Spring
3HAB 3662-1
111
Cable guide upper arm
3HAB 5928-1
112
Cover
3HAC 4337-1
114
Instruction plate
3HAC 2589-1
115
Serial meas. board
3HAB 3700-1
116
9ADA 629-45
6.1x20x2
IRB 2400/10/16
M5x16
23
Itm
Qty
Name
Art. no.
117
Battery unit
4944 026-4
118
14
Hexagon nut with flange
9ADA 290-1
M5 fzb
119
12
Cable straps, outdoor
2166 2055-3
L=208 mm
121
Push button unit
3HAC 0017-1
122
Distance bolt
2125 2052-198
123
Push button cover
3HAC 2744-1
125
Cable straps, outdoors
2166 2055-7
129
Signal cable SMB
3HAC 7819-1
132
Dust cap
3HAC 7561-3
133
Dust cap
3HAC 7561-4
134
15
Torx pan head screw
9ADA 618-56
M6x16 8.8
135
Hex socket head pan screw
9ADA 183-34
M8x12 8.8
136
9ADA 629-34
M4x12 Ext. conn.
137
63
9ADA 629-44
M5x12
138
2166 2055-1
L=101 mm
139
Coupling
3HAB 3333-20
Locking liquid
1269 0014-412
Loctite 542
D=11.4 - 13
140
M5x15
8.9x780
141
Protective hood
2522 2101-8
147
Gasket
3HAC 4419-1
149
Gasket
3HAB 7160-1
Flange sealing
1234 0011-116
Loctite 574
19x0.18
150
151
Adhesive tape
1169 9198-301
152
Bracket
3HAB 5921-1
156
Parallel pin
3HAC 3785-1
157
Adaptor, customer cabling
3HAB 7328-1
157
Cover protection
3HAC 6823-1
158
Adaptor, power cabling
3HAB 2809-1
159
Protection cover
3HAC 7816-1
160
Sealing
3HAC 5479-3
161
Sealing
3HAC 5479-4
168
Protective hood
3HAC 3189-1
Suspended
169
Gasket
3HAB 9040-1
Standard
170
Cover
3HAC 0048-1
Profile
1866 1903-1
171
Axes 4-6Upper
24
Remark
Foundry
120 mm
Arm IRB 2400L
Itm
Qty
Name
Art. no.
Remark
45
Sealing
3HAC 10089-2
46
Damper axis 3
3HAB 5511-1
47
Bracket
3HAC 0001-1
48
Sealing
3HAC 10088-4
49
Hex socket counters, head
2121 2852-449
M8x16 8.8
Itm
Qty
Name
Art. no.
Remark
50
Locking washer
3HAB 5523-1
SS 1914-04
6 ml, Loctite 243
51
Locking liquid
3HAB 7116-1
52
Gasket
3HAC 4429-1
53
Cable unit axes 4-6
3HAC 9328-1
54
Torx pan head screw
9ADA 618-46
M5x20 8.8
55
2166 2055-1
2.5x101
Adhesive tape
1169 9198-301
500 mm, 19x0.18
56
57
Cover
3HAB 6491-1
57
Cover with lamp unit
3HAC 2774-1
58
10
9ADA 629-44
M5x12
59
9ADA 183-22
M6x10
60
Motor unit axis 6
3HAC 10602-2
Motor unit axis 6
3HAC 021731-001 10/16 kg, Yaskawa
Motor unit axis 6
3HAC 021741-001 5 kg, Yaskawa
Upper arm without wrist and

motors
3HAC 1581-1
13
Disc spring
3HAB 3731-14
67.5x50.5x0.7
18
Wrist
3HAB 9439-1
Standard
18
Wrist
3HAB 9398-1
Foundry
19
O-ring
3HAB 3772-12
Nitrile rubber 126x4
20
3HAB 3402-38
M8x30 8.8
21
15
Plain washer
9ADA 312-7
8.4x16x1.6
25
Motor unit axis 5
3HAC 10600-1
10 kg
Motor unit axis 5
3HAC 10601-1
16 kg
Motor unit axis 5
Motor unit axis 5
3HAC 021722-001 10/16 kg, Yaskawa
Motor unit axis 4
3HAC 10602-1
Motor unit axis 4
Gleitmo 610
26
Motor unit axis 4
3HAC 021353-001 10/16 kg, Yaskawa
27
O-ring
3HAB 3772-1
Nitrile rubber
34.2x3
28
12
Plain washer
9ADA 312-6
6.4x12x1.6
29
12
3HAB 3409-26
M6x25 12.9
Gleitmo 610
30
Damper axis 4
3HAB 5544-1
32
3HAB 3402-36
Lubricating oil
3HAC 0860-1
2300 ml
R1/4
M8x20 8.8
Gleitmo 610
33
34
Magnetic plug
2522 122-1
35
Sealing ring
2152 2031-6
39
Bearing grease
3HAB 3537-1
50 g
40
Flange sealing
1234 0011-116
30 ml, Loctite 574
25
Itm
Qty
Name
Art. no.
41
Sealing ring without dust lip
3HAC 7877-2
42
Taper roller bearing
3HAA 2103-15
43
Parallel bar
3HAC 1564-1
44
Spherical roller bearing
3HAA 2167-12
PartsDrive
Remark
32007 X
22206 CC
unit IRB 2400/10/16
Itm
Qty
Name
Art. no.
Tubular shaft
3HAC 0235-1
Back-up ring
3HAB 6354-1
Sealing ring
3HAB 3732-13
Ball bearing
2213 253-12
Remark
99x10.5
V-110-L
105x130x13
61821-2RSI
Cover plug
2216 264-14
IRB 2000
Housing, axis 4
3HAC 0236-1
Spacer
2159 167-61
D=115/105,
T=0.05
Spacer
2159 167-62
D=115/105,
T=0.1
Spacer
2159 167-63
D=115/105,
T=0.5
10
Gear, axis 4, step 2
3HAB 3210-1
11
Damper, axis 4
3HAB 6356-1
12
3HAB 3402-24
M6x16 8.8
Gleitmo 610
13
10
Plain washer
9ADA 312-6
6.4x12x1.6
14
3HAB 3402-30
M6x45 8.8,
Gleitmo 610
A2F
Drive unit axis 5-6Drive
unit IRB 2400L
Itm
Qty
Name
Art. no.
Remark
45
10
2166 2055-1
2.5x101
Polyamide 6.6
black
46
Clamp
2166 2018-8
D=6
5562-00-04
47
Clamp
2166 2018-2
D=11
5562-00-07
48
Bracket, axes 5-6
3HAB 3230-1
49
9ADA 629-47
50
Parallel bar
3HAC 1563-1
51
Damper, axis 3
3HAB 5511-1
M5x25 8 A2F
Itm
Qty
Name
Art. no.
Remark
52
9ADA 183-22
M6x10 8.8
53
Spherical roller bearing
3HAA 2167-12
54
Sealing
3HAC 10088-4
55
Sealing
3HAC 10089-2
56
Locking washer
3HAA 2356-11
9x35x3
57
3HAB 3402-36
M8x20 8.8
Gleitmo 610
58
Cable bracket upper arm
3HAB 5927-1
59
Cable unit axes 4-6
3HAC 9330-1
59
Cable unit axes 4-6
3HAC 13052-1
60
Gasket
3HAB 4429-1
61
2166 2055-3
15
Drive unit axis 5-6
16
Motor unit, axis 4
3HAC 11864-1
17
9ADA 183-14
M5x16 8.8, A2F
18
O-ring
2152 2011-414
44.2x3, Nitrile
rubber
23
Gear unit, axis 4
3HAB 3380-1
24
Plain washer
9ADA 312-7
8.4x16x1.6, A2F
25
9ADA 183-38
M8x30 8.8, A2F
28
Cover
3HAB 6355-1
30
Lubricating oil
1171 2016-604
30 ml
31
Locking liquid
3HAB 7116-1
Loctite 243
32
Locking liquid
1269 0014-413
Loctite 638
34
Flange sealing
1234 0011-116
Loctite 574
35
Bearing grease
3HAB 3537-1
Shell Retinax MS
A2F
D=30/62 W=20
22206 CC
Standard
Wire feeder
36
Wrist, 5 kg
3HAC 10814-1
Standard and
Foundry
37
3HAB 3402-25
M6x20 8.8,
Gleitmo 610
38
Cover
3HAB 4350-1
Cover with lamp unit
3HAC 2743-1
Option
39
39
9ADA 629-44
M5x12 8
40
Cover
3HAB 4405-1
43
Sealing ring (without dust lip)
3HAB 7877-2
D=42/55 W=8
Nitrile rubber
44
Taper roller bearing
3HAA 2103-15
D=35/62 W=18
32007 X
27
Axes 5-6Limit
Switch
Itm
Qty
Name
Art. no.
Remark
Drive shaft unit, axes 5-6
3HAC 11804-1
Motor unit axes 5-6
3HAC 11865-1
Motor plate
3HAA 2504-1
Hexagon nut
9ADA 267-5
M5 8. A2F
10
3HAB 3402-14
M5x16 8.8
Gleitmo 610
10
Plain washer
9ADA 312-5
5.3x10x1. A2F
Gear belt
3HAA 2393-1
Qty
Name
Art. no.
Switches
Holder ring
3HAC 0305-1
Hexagon screw, button head
3HAC 0596-31
Cam, blank
3HAB 8086-1
24
Torx pan head screw
9ADA 618-55
Attachment plate
3HAC 0982-1
Torx pan head screw
9ADA 618-56
Position switch 1
3HAC 6447-1
Position switch 1-3
3HAC 6448-1
9ADA 183-5
Shims-sheet
3HAB 7478-1
10
9ADA 629-42
M5x8
11
Clamp
2166 2018-9
D=8
12
2166 2055-3
4.8x208
13
Assembly instruction
3HAB 8372-1
Incl. in the
delivery.
14
Torx pan head screw
9ADA 618-59
M6x30.
Axis 1
Itm
28
Remark
M8x12
M6x12
M6x16
M4x16
3 Foldouts
3 Foldouts
29
3 Foldouts
30
4 Circuit diagram
4 Circuit diagram
31
Product Manual IRB 2400
Manipulator Circuit Diagram
LIST OF CONTENTS
No. of Sheets 13
Sheet no.
101
3HAC 6670-3 Rev.01
CONNECTION POINT LOCATIONS

No. of Sheets 13
Sheet no.
102
3HAC 6670-3 Rev.01
BREAK UNIT
No. of Sheets 13
Sheet no.
103
3HAC 6670-3 Rev.01
MOTOR AXIS 1 - 3
No. of Sheets 13
Sheet no.
104
3HAC 6670-3 Rev.01
SERIAL MEASUREMENT BOARD

No. of Sheets 13
Sheet no.
105
3HAC 6670-3 Rev.01
MOTOR AXIS 4 - 6, 1.5 - 10 / 16

No. of Sheets 13
Sheet no.
106
3HAC 6670-3 Rev.01
FEED- BACK AXIS 4 - 6, 1.5 10 / 16

No. of Sheets 13
Sheet no.
107
3HAC 6670-3 Rev.01
MOTOR AXIS 4 - 6, 1.8 - 5

No. of Sheets 13
Sheet no.
108
3HAC 6670-3 Rev.01
FEED - BACK AXIS 4 - 6, 1.8 - 5

No. of Sheets 13
Sheet no.
109
3HAC 6670-3 Rev.01
CUSTOMER CONNECTIONS
No. of Sheets 13
Sheet no.
110
3HAC 6670-3 Rev.01
INTEGRATED WIREFEED CABLING (OPTION)
No. of Sheets 13
Sheet no.
111
3HAC 6670-3 Rev.01
POS. INDICATOR AXIS 1 (OPTION)

No. of Sheets 13
Sheet no.
112
3HAC 6670-3 Rev.01
EXTERNAL CONNECTIONS (OPTIONS)

No. of Sheets 13
Sheet no.
113
3HAC 6670-3 Rev.01
3HAC 022031-001, Revision A, en

ABB Automation Technologies AB
Robotics
S-721 68 VSTERS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax:
+46 (0) 21 132592

Product Manual (Part 2 of 2), Reference Information: Articulated Robot

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Product Manual (Part 2 of 2), Reference Information: Articulated Robot

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Product manual (part 2 of 2), reference information

Product manual (part 2 of 2), reference information

The information in this manual is subject to change without notice and

Copyright 2004 ABB All right reserved.

3HAC 022031-001 Revision: A

Who should read this manual?

be a trained maintenance/repair craftsman

have the required knowledge of mechanical and electrical installation/repair/

Useful information when performing installation, maintenance or

Complete list of manipulator parts, shown in the exploded views or

Detailed illustrations of the manipulator with reference numbers to

Circuit Diagram of the manipulator.

3HAC 022031-001 Revision: A

Section Document references is completed with article numbers for calibration

3HAC 022031-001 Revision: A

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

Installation and commissioning (descriptions of mechanical installation, electrical

Maintenance (descriptions of all required preventive maintenance procedures

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Product

Foldouts or exploded views

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

3HAC 022031-001 Revision: A

Product documentation, M2004

Product documentation, M2004

Installation and commissioning (descriptions of mechanical installation, electrical

Maintenance (descriptions of all required preventive maintenance procedures

Repair (descriptions of all recommended repair procedures including spare parts)

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

Reference information (article numbers for documentation referred to in Product

Foldouts or exploded views

RAPID Overview: An overview of the RAPID programming language.

RAPID reference manual part 1: Description of all RAPID instructions.

Technical reference manual - System parameters: Description of system

The purpose of the application (what it does and when it is useful)

3HAC 022031-001 Revision: A

Product documentation, M2004

How to use the application

Examples of how to use the application

Operators manual - IRC5 with FlexPendant

Operators manual - RobotStudioOnline

Trouble shooting Manual for the controller and robot

Robot fundamentals (describing the fundamental aspects, functions, concept and

3HAC 022031-001 Revision: A

3HAC 022031-001 Revision: A

1.2. Applicable Safety Standards

ISO10218, Jan. 1992, Industrial Robot Safety

ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing

DIN 19258 - Interbus-S, International Standard

Standards, safety fence

ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing

Standards, robot cell

Pr EN 999 Safety of machinery - The positioning of protective equipment in respect

EN 1088 Safety of machinery - Interlocking device associated with guards principles

3HAC 022031-001 Revision: A

1.3. Unit conversion

3HAC 022031-001 Revision: A

1.4. Screw joints

Molycote 1000 (molybdenum disulphide grease)