IRC5-IRB1400 Prod Man 3HAC021111-001 Procedures Rev - en

Product manual (part 1 of 2), procedures
Articulated robot
IRB 1400
M2000, M2004

Product manual (part 1 of 2)

Procedures
3HAC 021111-001
Revision -
Articulated robot
IRB 1400
M2000
M2004
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
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
0.0.2 Product documentation, M2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
0.0.3 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1: Safety, service
13
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

1.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.2: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

1.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.2.6 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.3: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.3.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

1.3.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.3.3 Emergency release of the manipulators arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.3.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.3.7 Work inside the manipulators working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
1.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2: Installation and commissioning
21
2.0.1 Transporting and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

2.0.2 Stability / Risk of Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.0.3 System CD ROM and Diskette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
2.0.4 Transport Locking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.1: On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.1.1 Lifting the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

2.1.2 Turning the Manipulator (Inverted Suspension Application) . . . . . . . . . . . . . . . . . . . . . . . . .26
2.1.3 Assembling the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2.1.4 Suspended Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2.1.5 Stress Forces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
2.1.6 Amount of Space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2.1.7 Manually engaging the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
2.1.8 Restricting the Working Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
2.1.9 Mounting Holes for Equipment on the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
2.1.10 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
2.2: Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.2.1 Air supply and signals for extra equipment to upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.2.2 Connection of Extra Equipment to the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
3: Maintenance
41
3.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

3.0.2 Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3.1: Instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3.1.1 Oil in gears 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

3.1.2 Greasing axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
3HAC 021111-001
Table of Contents
3.1.3 Lubricating spring brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.1.4 Changing the battery in the measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.1.5 Checking the mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4: Repair
49
4.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.1.2 Instructions for reading the following sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1.3 Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.1.4 Fitting new Bearings and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.1.5 Instructions for tightening Screw Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.1.6 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1.7 Checking for play in gearboxes and wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2: Axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.2.1 Changing the motor of axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.2.2 Changing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.2.3 Position indicator in axis 1 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.2.4 Replacing the mechanical stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3: Axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.3.3 Dismantling the lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.3.4 Changing the bearings in the upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.3.5 Dismantling the balancing springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.4: Axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.4.3 Dismantling the parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.4.4 Changing the tie rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.4.5 Dismantling the complete upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.5: Axis 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.5.1 Changing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.5.2 Changing the intermediate gear including sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.5.3 Dismantling the drive gear on the tubular shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.5.4 Dismantling the tubular shaft and changing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.6: Cabling and serial measuring board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.6.1 Changing serial measuring boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.6.2 Changing the cabling in axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.6.3 Changing the cabling in axes 4, 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.7: The wrist and axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.7.1 Dismantling the wrist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4.7.2 Dismantling the complete drive mechanism of axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.7.3 Changing the motor or driving belt of axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.7.4 Measuring play in axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.8: Motor units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5: Calibration, M2000
91
5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.1: Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.1.1 How to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

5.1.2 Calibration, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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Table of Contents
5.2: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
5.2.1 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

5.2.2 Directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
5.2.3 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
5.2.4 Positions and directions of sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
5.2.5 Initialization of Levelmeter 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
5.3: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
5.3.1 Calibration, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

5.3.7 Fine calibration procedure on TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
5.3.8 Resetting of Levelmeter 2000 and sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
5.3.9 Updating the revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
5.4: After calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
5.4.1 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

125
6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

7: Alternative calibration
127
7.0.1 Alternative calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

7.0.2 Alternative calibrating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
7.0.3 New calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
7.0.4 New calibration offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
7.0.5 Retrieving offset values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
3HAC 021111-001
Table of Contents
3HAC 021111-001
0.0.1 Overview
0.0.1 Overview
About this
manual
Usage
Who should read

this manual?
Prerequisites
Organization of
chapters
This manual contains instructions for
mechanical and electrical installation of the manipulator
maintenance of the manipulator
mechanical and electrical repair of the manipulator.
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 and calibration.
This manual is intended for:
installation personnel
maintenance personnel
repair personnel.
The reader should...
be a trained maintenance/repair craftsman
have the required knowledge of mechanical and electrical installation/repair/maintenance work.
The manual is organized in the following chapters:
Chapter
Contents
Safety, service
Safety information
Installation and commissioning
Information about installation of the manipulator.
Maintenance
Information about maintenance work, including maintenance schedules.
Repair
Information about repair work.
Calibration
Information about calibration of the manipulator.
Decommissioning
Environmental information about the manipulator.
Reference
Document Id
References
3HAC 021111-001
Revision -
0.0.1 Overview
Revisions
Revision
Description
First edition.
Replaces previous product manual 3HAC 7617-1
Changes made in the material from the previous manuals:
Model M2004 implemented.
Revision -
3HAC 021111-001
0.0.2 Product documentation, M2000
General
The complete product documentation kit for the M2000 robot system, including controller,
manipulator and any hardware option, consists of the manuals listed below:
Hardware
manuals
All hardware, manipulators and controller cabinets, will be delivered with a Product manual
that 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 periodicity)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning).
Product manual, reference information
Software manuals
Reference information (article numbers for documentation refered to in Product manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams.
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.
Hardware option
manual
Each hardware option 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.
3HAC 021111-001
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Revision -
3HAC 021111-001
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 one delivery of robot products will not contain
all documents listed, but only some of them.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware
manuals
All hardware, manipulators and controller cabinets, will be delivered with a Product manual
that 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 periodicity)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning).
Product manual, reference information
RobotWare
manuals
Application
manuals
Reference information (article numbers for documentation refered to in Product manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams.
The following manuals describe the robot software in general and contain reference information about it:
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.
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:
3HAC 021111-001
The purpose of the application (what does it do and when is it 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
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11
Operating
Manuals
Miscellaneous
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, and include:
Operating Manual - IRC5 with FlexPendant
Operating Manual - RobotStudioOnline
Trouble shooting Manual for the controller and manipulator
A number of manuals provide generic descriptions of the robot and robot system. These
include:
12
Robot fundamentals (describing the fundamental aspects, functions, concept and

similar, of a robot system to provide a basic understanding of the robot system)
Revision -
3HAC 021111-001
1 Safety, service
1.0.1 Introduction
1: Safety, service
1.0.1 Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
The chapter "Safety, service" is divided into the following sections:

1. General information contains lists of:
Safety, service -general
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 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)
3HAC 021111-001
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1 Safety, service
1.1.1 Safety, service - General
1.1: General information

1.1.1 Safety, service - General
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.
1.1.2 Limitation of Liability
General
Any information given in this information product 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.
1.1.3 Related information
General
The list below specifies documents which contain useful information:
Documents
Type of information
Detailed in document
Section
Installation of safety devices
Product manual for the manipulator Installation and commissioning
Changing robot modes
Users Guide
Start-up
Restricting the working space Product manual for the manipulator Installation and commissioning
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3HAC 021111-001
1 Safety, service
1.2.1 Safety risks related to gripper
1.2: Safety risks

1.2.1 Safety risks related to gripper
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
1.2.2 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.
1.2.3 Safety risks related to pneumatic/hydraulic systems
General
Residual energy
Safe design
3HAC 021111-001
Special safety regulations apply to pneumatic and hydraulic systems.
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.
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.
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1 Safety, service
1.2.4 Safety risks during operational disturbances
1.2.4 Safety risks during operational disturbances
General
Qualified personnel
Extraordinary
risks
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.
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.
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.
1.2.5 Safety risks during installation and service
General risks
during installation and service
Nation/region
specific regulations
Non-voltage
related risks
16
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.
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.
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 parts
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.
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3HAC 021111-001
1 Safety, service
1.2.6 Risks associated with live electric parts
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.
1.2.6 Risks associated with live electric parts
Voltage related
risks, general
Voltage related
risks, controller
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.
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, manipulator
A danger of high voltage is associated with the manipulator in:
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.
3HAC 021111-001
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)
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17
1 Safety, service
1.3.1 Safety fence dimensions
1.3: Safety actions

1.3.1 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.
1.3.2 Fire extinguishing

Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator or controller)!
1.3.3 Emergency release of the manipulators arm
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section Manually releasing the brakes in the Product
manual for the manipulator.
The manipulator arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar.
Increased injury
18
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!
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3HAC 021111-001
1 Safety, service
1.3.4 Brake testing
1.3.4 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.
1.3.5 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.
1.3.6 Safe use of the Teach Pendant Unit

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
robots working space. This is to prevent anyone else taking control over the robot without
the programmer knowing.
3HAC 021111-001
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1 Safety, service
1.3.7 Work inside the manipulators working range
1.3.7 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 speedmay 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 19.
1.3.8 Signal lamp (optional)
Description
A signal lamp with an yellow fixed light can be mounted on the manipulator, as a safety
device. The signal lamp is required on an UL/UR approved robot.
Function
The lamp is active in MOTORS ON mode.
Further
information
Further information about the MOTORS ON/MOTORS OFF mode may be found in the chapter Description, Control System in the Product manual for the controller.
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3HAC 021111-001
2 Installation and commissioning

2.0.1 Transporting and Unpacking
2: Installation and commissioning

2.0.1 Transporting and Unpacking
NB!
Before starting to unpack and install the robot, read the safety regulations and other
instructions very carefully. These are found in separate sections in the Users Guide and
Product manual.
The installation shall be made by qualified installation personnel and should conform
to all national and local codes.
When you have unpacked the robot, check that it has not been damaged during transport or while unpacking.
Operating
conditions
Storage
conditions
Parameter
Value
Ambient temperature
+5 to +45
Relative humidity
Max. 95% at constant temperature
If the equipment is not going to be installed straight away, it must be stored in a dry area at
an ambient temperature between -25C and +55C.
When air transport is used, the robot must be located in a pressure-equalized area.
Weight
3HAC 021111-001
The net weight of the manipulator is approximately: 225 kg
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21

2.0.2 Stability / Risk of Tipping
2.0.2 Stability / Risk of Tipping

When the manipulator is not fastened to the floor and standing still, the manipulator is not
stable in the whole working area. When the arms are moved, care must be taken so that the
centre of gravity is not displaced, as this could cause the manipulator to tip over.
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3HAC 021111-001

2.0.3 System CD ROM and Diskette
2.0.3 System CD ROM and Diskette

The system CD ROM and the manipulator parameter disk are delivered with the robot system.
See section RobotWare CD-ROM in the Product manual for the controller.
Art. no. for the manual is detailed in section Document references in the Product manual,
reference information.
3HAC 021111-001
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23

2.0.4 Transport Locking Device
2.0.4 Transport Locking Device

At delivery, axis 2 (= lower arm) is equipped with a transport locking device (see figure
below).
Remove the transport locking device before operating the robot.
Transport locking
device
Figure 1: Transport Locking Device, Axis 2.
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3HAC 021111-001

2.1.1 Lifting the Manipulator
2.1: On-site installation

2.1.1 Lifting the Manipulator
The best way to lift the manipulator is to use lifting straps and a traverse crane. Attach the
straps to the special eye bolts on the gear boxes for axes 2 and 3 (see figure below). The lifting
strap dimensions must comply with the applicable standards for lifting.
Never walk under a suspended load.
Lifting eye
IRB 1400H
Lifting eye
IRB 1400
Figure 2: Lifting the Manipulators using a Traverse Crane.
3HAC 021111-001
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25

2.1.2 Turning the Manipulator (Inverted Suspension Application)
2.1.2 Turning the Manipulator (Inverted Suspension Application)

N.B! Only possible with IRB 1400H.
A special tool is recommended when the manipulator is to be turned for inverted mounting
(ABB article number 3HAB 3397-1).
The tool is attached to the outsides of the gearboxes for axes 2 and 3 using six (M8x25) bolts
and washers. Tightening torque 25 Nm.
The manipulator is lifted with a fork lift or a crane (see figure below).
Note also the positions of the arm system.
(Fork lift)
M8x25 (x3) on both sides
Appr. R=860
Tool 3HAB 3397-1
Appr. R=580
Figure 3: Turning the Manipulator.
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3HAC 021111-001

2.1.3 Assembling the robot
2.1.3 Assembling the robot
Manipulator
The manipulator must be mounted on a level surface with the same hole layout as shown in
Figure 4. The levelness requirement of the surface is as follows:
0.5
38
20
35
18,5
455
245
210
35 H8
400
200
18.5 H7
Figure 4: Bolting down the Manipulator.
The manipulator is bolted down by means of three M16 bolts.
Suitable bolts
M16 8.8
Tightening torque
190 Nm
Two guide sleeves, ABB art. no. 2151 0024-169, can be fitted to the two rear bolt holes, to
allow the same robot to be re-mounted without having to re-adjust the program.
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 defined
in this chapter, section Stress Forces on page 29.
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27

2.1.4 Suspended Mounting
2.1.4 Suspended Mounting

The method for mounting the manipulator in a suspended position is basically the same as for
floor mounting.
With inverted installation, make sure that the gantry or corresponding structure is rigid
enough to prevent unacceptable vibrations and deflections, so that optimum performance can be achieved.
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3HAC 021111-001

2.1.5 Stress Forces
2.1.5 Stress Forces
Stiffness
The stiffness of the foundation must be designed to minimize the influence on the dynamic
behaviour of the robot.
TuneServo can be used for adapting the robot tuning to a non-optimal foundation.
IRB 1400 and IRB

1400H
Force
Endurance load (in operation) Max. load (emergency stop)
Fxy
1500 N
2000 N
Fz (upright)
2800 500 N
2800 700 N
Fz (suspended)
-2800 800 N
-2800 1000 N
Torque
Endurance load (in operation) Max. load (emergency stop)
Mxy
1800 Nm
2000 Nm
Mz
400 Nm
500 Nm
Fxy and Mxy are vectors that can have any direction in the xy plane.
Z
Figure 5: The Directions of the Stress Forces.
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29

2.1.6 Amount of Space required
2.1.6 Amount of Space required

The amount of working space required to operate the manipulator is illustrated in the figures
below. The working range for axis 1 is +/- 170.
NB! There are no software or mechanical limits for the working space under the base of
the manipulator.
Manipulator
1793
1195
50
150
511
1008
1444
1282
733
254
150
150
1051
770
1127
1221
1645
Axis 1 +145o
-135o
Axis 1 170o
Figure 6: The Amount of working Space required for the Manipulator.
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3HAC 021111-001

2.1.7 Manually engaging the brakes
2.1.7 Manually engaging the brakes

All axes are equipped with holding brakes. If the positions of the manipulator axes are to be
changed without connecting the controller, an external voltage supply (24 V d.c.) must be
connected to enable engagement of the brakes. The voltage supply should be connected to the
contact at the base of the manipulator (see figure below).
Note! Be careful not to interchange the 24V and 0V pins! If they are mixed up, damage
can be caused to electrical components.
+24 V B8
0 V C10
Figure 7: Connection of External Voltage to enable Engagement of the Brakes.
External power must be connected according to Figure 7. Incorrectly connected power

can release all brakes, causing simultaneously movement of all axes.
When the controller or the voltage supply is connected as illustrated above, the brakes can be
engaged using the push-button on the manipulator, see Figure 8.
WARNING: Be very careful when engaging the brakes. The axes become activated very
quickly and may cause damage or injury.
Brake release button
Figure 8: Location of the Brake Release Button.
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2.1.8 Restricting the Working Space

When installing the manipulator, 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, both mechanically and using software. Installation of an optional extra stop for the
main axes 1, 2 and 3 is described below.
Limiting the working space using software is described in the System Parameters in the
Users Guide.
Axis 1
The range of rotation for axis 1 can be limited mechanically by fitting extra stop lugs to the
base, see Figure 9.
Instructions for necessary machining and mounting are supplied with the kit.
NB! The original stop lug must never be removed.
Extra stop lug for axis 1
Figure 9: Mechanically limiting Axis 1.
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3HAC 021111-001

Axis 2
The working range of axis 2 can be limited mechanically by fitting extra stop lugs to the under
arm (see Figure 10). The lugs limit the arm movements in intervals of 20. (20 = 1 lug, 40
= 2 lugs, etc.)
Instructions for doing this are supplied with the kit.
Under arm
Extra stop lugs
Figure 10: Mechanically limiting Axis 2.
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33

Axis 3
The working range of axis 3 can be limited mechanically by fitting a stop lug under the
parallel arm (see Figure 11). Axis 3 is limited upwards to 0 or -10 degrees above the horizontal plane.
Instructions for doing this are supplied with the kit.
Extra stop lug
Figure 11: Extra Stop Lug for limiting Axis 3.
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3HAC 021111-001

2.1.9 Mounting Holes for Equipment on the Manipulator
2.1.9 Mounting Holes for Equipment on the Manipulator
NB! Never drill a hole in the manipulator without first consulting ABB.
A
135
Mounting holes
for equipment
M8 (2x)
Depth 16
IRB 1400H
120
120
IRB 1400
135
Mounting holes
for equipment
M8 (2x)
Depth 16
Mounting holes
for equipment, both sides
M8 (3x), R=75
Depth 16
120o(3x)
15o
Figure 12: Mounting Holes for Customer Equipment.
D=6 H7
0.05 B
M6 (4x)
0.3 C
10
D=12
R 20
D=50 h8
D=25 H8
45o
A
2
90o (4x)
0.06 B
A-A
Figure 13: The mechanical Interface (Mounting Flange).
3HAC 021111-001
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35

2.1.10 Loads
2.1.10 Loads
Regarding load diagram, permitted extra loads (equipment) and locations of extra loads
(equipment), see the Product Specification for IRB 1400. The loads must also be defined in
the soft ware, see Users Guide.
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3HAC 021111-001

2.2.1 Air supply and signals for extra equipment to upper arm
2.2: Customer connections on manipulator

Option 041
Hose for compressed air is integrated into the manipulator. There is an inlet at the base and
an outlet on the upper arm housing. Connections: R1/4 in the upper arm housing and at the
base. Max. 8 bar. Inner hose diameter: 6.5 mm.
For connection of extra equipment on the manipulator, there are cables integrated into the
manipulators cabling.
Option 042
Number of signals
12 signals, 49V, 500 mA
Connector on upper arm:
FCI 12-pin UT001412SHT
Connector on robot base:
FCI 12-pin UT001412PHT
Control cabling to arc welding wire-feeder is integrated into the manipulators cabling.
Control signals
Number of signals:
16 signals, 49V, 500 mA
Connector on upper arm housing:
FCI 23-pin UTG61823PN
FCI 23-pin UT001823SHT
Power signals
Number of signals:
12 signals, 300V, 4A
Connector on upper arm housing:
FCI 12-pin socket UTG61412SN
FCI 12-pin UT001412PHT
This option (042) is not available for IRB 1400H.
3HAC 021111-001
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37

R1.CS
Air (only option 041)
R2.CP (only option 042)
R2.CS
Air (only option 041)
R2.CP (only option 042)
Figure 14: Location of Customer Connections.

To connect power and signal conductors to the manipulator base and to the upper arm
connectors, the following parts are recommended:
ABBs recommended contact set, for connector R2.CS, has Art. No. 3HAC 12583-1.
ABBs recommended contact set, for connector R1.CS, has Art. No. 3HAC 12493-1.
The complete contact set (option) contains:

Pins for cable area 0.13 - 0.25 mm2
Shrinking hose bottled shaped
Shrinking hose, angled,
which corresponds to item 4, 5, 6, 7, 8 and 9 according to Figure 15.
Customer side
4, 5
Manipulator side
1, 3
7
Figure 15: FCI Connector
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3HAC 021111-001

2.2.2 Connection of Extra Equipment to the Manipulator

Technical data for customer connections.
Signals
Conductor resistance
< 3 ohm, 0.154 mm2
Max. voltage
50 V AC/DC
Max. current
250 mA
Connections on
Upper Arm
R2.CS
Figure 16: Customer Connections on Upper Arm.
3HAC 021111-001
Customer Contact on
Manipulator Base
(Cable not supplied)
Signal
Name
Customer Contact
Customer Terminal on Upper Arm, R2
Controller (optional)
CSA
XT5.1
R2.CS.A
R1.CS.A
CSB
XT5.2
R2.CS.B
R1.CS.B
CSC
XT5.3
R2.CS.C
R1.CS.C
CSD
XT5.4
R2.CS.D
R1.CS.D
CSE
XT5.5
R2.CS.E
R1.CS.E
CSF
XT5.6
R2.CS.F
R1.CS.F
CSG
XT5.7
R2.CS.G
R1.CS.G
CSH
XT5.8
R2.CS.H
R1.CS.H
CSJ
XT5.9
R2.CS.J
R1.CS.J
CSK
XT5.10
R2.CS.K
R1.CS.K
CSL
XT5.11
R2.CS.L
R1.CS.L
CSM
XT5.12
R2.CS.M
R1.CS.M
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39

Connection of
Signal Lamp on
Upper Arm
(Option)
R3.H1 +
R3.H2 -
Signal lamp
Figure 17: Location of Signal Lamp.
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3HAC 021111-001
3 Maintenance
3.0.1 Introduction
3: Maintenance
3.0.1 Introduction
The robot is designed to be able to work under very demanding circumstances with a minimum of maintenance. Nevertheless, certain routine checks and preventative maintenance
must be carried out at given periodical intervals, see the table below.
3HAC 021111-001
The exterior of the robot should be cleaned as required. Use a vacuum cleaner or
wipe it with a cloth. Compressed air and harsh solvents that can damage the
sealing joints, bearings, lacquer or cabling must not be used.
Check that the sealing joint and cable bushings are really airtight so that dust and
dirt are not sucked into the cabinet.
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3 Maintenance
3.0.2 Maintenance Intervals
3.0.2 Maintenance Intervals
Equipment
Check Check
twice/ once/
year
year
Mechanical stop
axis 1
X1
Cabling
X2
Maintenance
Maintenance
every 2000 hrs every 4000 hrs
or 6 months
or 1 year
Gears axis 1-4
Maintenance
free
Lubrication of
spring brackets
Lubrication of
gears axis 5-6
X
3 years3
Replacement of
accumulator for
measuring system
42
Others
1)
Check that the mechanical stop is not bent.
2)
Inspect all visible cabling. Change if damaged.
3)
See section Changing the battery in the measuring system on page 46.
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3HAC 021111-001
3 Maintenance
3.1.1 Oil in gears 1-4
3.1: Instructions for maintenance

3.1.1 Oil in gears 1-4
The gearboxes are lubricated for life.
ABBs oil, art. No. 1171 2016-604, corresponds to:
Oil volume (BP),

floor-mounted
robot
BP: Energol GR-XP 320
Castrol: Alpha SP 320
Esso: Spartan EP 320
Klber: Lamora 320
Optimol: Optigear 320
Shell: Omala Oil 320
Texaco: Meropa 320
Statoil: Loaway EP
Gearbox
Volume
Axis 1
2,000 ml
Axis 2 and 3
1,700 ml
Axis 4
30 ml
Gearbox
Volume
Axis 1
2,700 ml
Axis 2 and 3
1,700 ml
Axis 4
30 ml
Oil volume (BP),

suspended robot
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3 Maintenance
3.1.2 Greasing axes 5 and 6
3.1.2 Greasing axes 5 and 6

Grease is pressed through the 3 nipples (1), see Figure 18. The tip nozzle of the greasing gun
should be of type Orion 1015063, or equivalent.
Volume: 2 ml (0.00053 US gallon)
(1)
Figure 18: Greasing Positions for Axes 5 and 6.
Type of grease: ABBs art. No. 3HAB 3537-1, corresponds to:

Shell Alvania WR2
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3HAC 021111-001
3 Maintenance
3.1.3 Lubricating spring brackets
3.1.3 Lubricating spring brackets

There are four lubrication places, located over and under the two balancing springs.
Type of grease: ABBs art. No. 3HAA 1001-294, corresponds to:
Optimol PDO
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3 Maintenance
3.1.4 Changing the battery in the measuring system

The battery to be replaced is located inside the base under the flange cover (see Figure 19).
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.
Set the robot to the MOTORS OFF operating mode. (This means that it will not
have to be coarse-calibrated after changing the battery.)
Remove the flange cover. All connections on the flange cover, except for the signal
contact for the serial link, R1.SMB, can be disconnected.
Remove one of the screws and loosen the two other screws holding the serial
measurement board. Push the unit to the side and remove it backwards. All
cables and contacts must remain intact. Note the ESD-protection (ESD = Electrostatic Discharge).
Loosen the battery terminals from the serial measuring board and cut the clasps
that keep the battery unit in place.
Install a new battery with two clasps and connect the terminals to the serial measuring board.
Refit the serial measurement board, flange cover and connections.
The Ni-Cd battery takes 36 hours to recharge; the mains supply must be switched
on during this time.
Flange cover
Figure 19: The Battery is located Inside the Base under the Flange Cover.
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 maximum 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. The estimated max. life time in years for the different lithium batteries and the recommended exchange interval is shown below:
46
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3HAC 021111-001
3 Maintenance
User type
Exchange 3-cell
Exchange 6-cell
1. Vacation (4 weeks) power off
Every 5 years
Every 5 years1
2. Weekend power off + user type 1
Every 2 years
Every 4 years
3. Nightly power off + user type 1 and 2
Every year
Every 2 years
1)
Because of material aging, the maximum life in service is 5 years.
Voltage of batteries, measured at power off:

Min.
Max.
Ni-Cd
7.0 V
8.7 V
Lithium
7.0 V
Exchange of the battery is done according to the beginning of this section.
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3 Maintenance
3.1.5 Checking the mechanical stop, axis 1
3.1.5 Checking the mechanical stop, axis 1

Check regularly, as follows:
That the stop pin is not bent.
If the stop pin is bent, it must be replaced by a new one. See section Replacing the mechanical
stop on page 62.
The article number of the pin is 3HAB 3258-1.
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4 Repair
4.1.1 General description
4: Repair
4.1: General information
The industrial robot system comprises two separate units: the control cabinet and the manipulator. The IRB 1400 is also available in a suspended version, IRB 1400H. Servicing the
mechanical unit is described in the following sections. Servicing the manipulator is described
in this manual.
When service on the IRB1400H is contemplated, a decision must be made in each particular
case whether the work can be carried out with the manipulator suspended or whether it must
be removed and the work done on the floor.
Lifting and turning the manipulator is described in section Lifting the Manipulator on page
25.
When servicing the manipulator, it is helpful to service the following parts separately:
The Electrical System
The Motor Units
The Mechanical System
The Electrical System is routed through the entire manipulator and is made up of two main
cabling systems; the power cabling and signal cabling. The power cabling feeds the motor
units of the manipulator axes. The signal cabling feeds the various control parameters, such
as axis positions, motor revs, etc.
The AC Motor Units provide the motive power for the various manipulator axes by means of
gears. Mechanical brakes, electrically released, lock the motor units when the robot is inoperative for more than 3 minutes during both automatic and manual operation.
The manipulator has 6 axes which makes its movements very flexible.
Axis 1 rotates the manipulator. Axis 2 provides the lower arms reciprocating motion. The
lower arm, together with the parallel arm and the parallel bracket, forms a parallelogram relative to the upper arm. The parallel bracket is mounted on bearings in the parallel arm and in
the upper arm.
Axis 3 raises the upper arm of the manipulator. Axis 4, located on the side of the upper arm,
rotates the upper arm. The wrist is bolted to the tip of the upper arm and includes axes 5 and
6. These axes form a cross and their motors are located at the rear of the upper arm.
Axis 5 is used to tilt and axis 6 to turn. A connection is supplied for various customer tools
on the tip of the wrist in the turn disc. The tool (or manipulator) can be pneumatically controlled by means of an external air supply (optional extra). The signals to/from the tool can
be supplied via internal customer connections (optional extras).
Note that the control cabinet must be switched off during all maintenance work on the
manipulator. The accumulator power supply must always be disconnected before performing any work on the manipulator measurement system (measurement boards,
cabling, resolver unit).
When any type of maintenance work is carried out, the calibration position of the manipulator
must be checked before the robot is returned to the operational mode.
3HAC 021111-001
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4 Repair
Take special care when manually operating the brakes. Make sure also that the safety
instructions described in this manual are followed when starting to operate the robot.
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4 Repair
4.1.2 Instructions for reading the following sections
4.1.2 Instructions for reading the following sections

The subsequent sections describe the type of on-site maintenance that can be performed by
the customers own maintenance staff. Some maintenance jobs require special experience or
specific tools and are therefore not described in this manual. These jobs involve replacing the
faulty module or component on-site. The faulty component is then transported to ABB for
service.
Calibration
The robot must be re-calibrated when a mechanical unit or part of one is replaced, when the
motor and feedback unit is disconnected, when a resolver error occurs, or when the power
supply between a measurement board and resolver is interrupted. This procedure is described
in detail in section Calibration, M2000 on page 91.
Any work on the robot signal cabling may cause the robot to move to the wrong positions.
After performing such work, the calibration position of the robot must be checked as
described in section Calibration, M2000 on page 91.
Tools
Two types of tools are required for the various maintenance jobs. It may be necessary to use
conventional tools, such as sockets and ratchet spanners, etc., or special tools, depending on
the type of servicing. Conventional tools are not discussed in this manual, since it is assumed
that maintenance staff have sufficient basic technical competence. Maintenance jobs which
require the use of special tools are, on the other hand, described in this manual.
Foldouts
The chapter on spare parts comes with a number of foldouts which illustrate the parts of the
robot. These foldouts are provided in order to make it easier for you to quickly identify both
the type of service required and the make-up of the various parts and components. The item
numbers of the parts are also shown on the foldouts.
In the subsequent sections, these numbers are referred to in angle brackets < >. If a reference
is made to a foldout, other than that specified in the paragraph title, the foldouts number is
included in the numeric reference to its item number; for example:
<5/19> or <10:2/5>. The digit(s) before the stroke refer to the foldout number.
The foldouts also include other information such as the article number, designation and
related data.
NB! This manual is not considered as a substitute for a proper training course. The information in the following chapters should be used only after an appropriate course has been completed.
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4 Repair
4.1.3 Caution
4.1.3 Caution
The mechanical unit contains several parts which are too heavy to lift manually. As
these parts must be moved with precision during any maintenance and repair work, it
is important to have a suitable lifting device available.
The robot should always be switched to MOTORS OFF before anybody is allowed to
enter its working space.
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3HAC 021111-001
4 Repair
4.1.4 Fitting new Bearings and Seals
Bearings
1. Do not unwrap new bearings until just before assembly, in order to prevent dust
and grit getting into the bearing.
2. Make sure that all parts of the bearing are free from burr dust, grinding dust and
any other contamination. Cast parts must be free from foundry sand.
3. Bearing rings, races and roller parts must not under any circumstances be subjected to direct impact. The roller parts must not be subjected to any pressure that
is created during the assembly.
Tapered Bearings
1. The bearing should be tightened gradually until the recommended pre-tensioning

is attained.
2. The roller parts must be rotated a specified number of turns both before
pre-tensioning and during pre-tensioning.
3. The above procedure must be carried out to enable the roller parts to slot into the
correct position with respect to the racer flange.
4. It is important to position the bearings correctly, because this directly affects the
service life of the bearing.
Greasing
Bearings
1. Bearings must be greased after they are fitted. Extreme cleanliness is necessary
throughout. High quality lubricating grease, such as Shell Alvania WR2
(ABBs art. No. 3537-1), should be used.
2. Grooved ball bearings should be greased on both sides.
3. Tapered roller bearings and axial needle bearings should be greased when they
are split.
4. Normally the bearings should not be completely filled with grease. However, if
there is space on both sides of the bearing, it can be filled completely with grease
when it is fitted, as surplus grease will be released from the bearing on start up.
5. 70-80% of the available volume of the bearing must be filled with grease during
operation.
6. Make sure that the grease is handled and stored correctly, to avoid contamination.
Seals
The most common cause of leakage is incorrect mounting.
Rotating Seals
1. The seal surfaces must be protected during transportation and assembly.

2. The seals must either be kept in their original packages or be protected well.
3. The seal surfaces must be inspected before mounting. If the seal is scratched or
damaged in such a way that it may cause leakage in the future, it must be
replaced.
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4 Repair
4. The seal must also be checked before it is fitted to ensure that:

5. The seal edge is not damaged (feel the edge with your finger nail),
6. The correct type of seal is used (has a cut-off edge),
7. There is no other damage.
8. Grease the seal just before it is fitted not too early as otherwise dirt and foreign
particles may stick to the seal. The space between the dust tongue and sealing
lip should 2/3-filled with grease of type Shell Alvania WR2 (ABBs art. No. 35371). The rubber coated external diameter must also be greased.
9. Seals and gears must be fitted on clean workbenches.
10.Fit the seal correctly. If it is fitted incorrectly, it may start to leak when pumping
starts.
11.Always use an assembling tool to fit the seal. Never hammer directly on the seal
because this will cause it to leak.
12.Use a protective sleeve on the sealing edge during assembly, when sliding over
threads, key-ways, etc.
Flange Seals and

Static Seals
1. Check the flange surfaces. The surface must be even and have no pores. The
evenness can be easily checked using a gauge on the fitted joint (without sealing
compound).
2. The surfaces must be even and free from burr dust (caused by incorrect machining). If the flange surfaces are defective, they must not be used as they will cause
leakage.
3. The surfaces must be cleaned properly in the manner recommended by ABB.
4. Distribute the sealing compound evenly over the surface, preferably using a
brush.
5. Tighten the screws evenly around the flange joint.
6. Make sure that the joint is not subjected to loading until the sealing compound has
attained the hardness specified in the materials specification.
O-rings
1. Check the O-ring grooves. The grooves must be geometrically correct, without
pores and free of dust and grime.
2. Check the O-ring for surface defects and burrs, and check that it has the correct
shape, etc.
3. Make sure the correct O-ring size is used.
4. Tighten the screws evenly.
5. Defective O-rings and O-ring grooves must not be used.
6. If any of the parts fitted are defective, they will cause leakage. Grease the O-ring
with Shell Alvania WR2 (ABBs art. No. 3537-1) before fitting it.
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4 Repair
4.1.5 Instructions for tightening Screw Joints
4.1.5 Instructions for tightening Screw Joints
General
It is extremely important that all screw joints are tightened using the correct torque.
Application
The following tightening torques must be used, unless otherwise specified in the text, for all
screw joints made of metallic materials.
The instructions do not apply to screw joints made of soft or brittle materials.
For screws with a property class higher than 8.8, the same specifications as for class 8.8. are
applicable, unless otherwise stated.
Screws treated
with Gleitmo
All screws in the manipulator that are tightened to a specified torque are treated with Gleitmo.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type
should be used.
Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip
coating disappears. Screws can also be treated with Molycote 1000.
When screwing in new screws without Gleitmo, these should first be lubricated with Molycote 1000 and then tightened to the specified torque.
Assembly
Screw threads sized M8 or larger should preferably be lubricated with oil. Molycote 1000
should only be used when specified in the text.
Screws sized M8 or larger should be tightened with a torque wrench, if possible.
Screws sized M6 or smaller may be tightened to the correct torque by personnel with sufficient mechanical training, without using torque measurement tools.
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4 Repair
4.1.6 Tightening Torques
4.1.6 Tightening Torques
Screws with
slotted or cross
recessed head,
property class 4.8
Screws with
hexagon socket
head, property
class 8.8
56
Dimension
Tightening Torque Nm
Without Oil
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension
Without Oil
With Oil
M3
M4
M5
5.5
M6
10
M8
24
22
M10
48
45
M12
83
78
M16
200
190
M20
410
400
M24
750
740
Revision -
3HAC 021111-001
4 Repair
4.1.7 Checking for play in gearboxes and wrist
4.1.7 Checking for play in gearboxes and wrist

When checking for play in gearboxes the brakes must be disengaged.
When trying to move an arm manually when the brakes are engaged, some play can be felt.
The play that can be felt is between the brake disk and the motor shaft, not in the gearbox
itself. This is because the rotating brake disk is connected to the motor shaft by splines. This
is why the brakes must be disengaged before testing for play in the gearboxes and wrist. The
brakes are disengaged by pressing the enable button on the teach pendant.
The play in the brake disk does not affect the robot motion or accuracy.
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4 Repair
4.2.1 Changing the motor of axis 1
4.2: Axis 1
See foldouts 1 and 5 (6 for IRB 1400H) in the list of spare parts.
The motor and the drive gear constitute one unit.
To dismantle
1. Remove the cover of the motor.

2. Loosen connectors R4.MP1 and R4.FB1.
3. Remove the connection box by unscrewing <5/160>.
4. Note the position of the motor before removing it.
5. Loosen the motor by unscrewing <1/10>.
To assemble
1. Check that the assembly surfaces are clean and the motor unscratched.
2. Release the brake, apply 24V DC to terminals 7 and 8 in the 4.MP1 connector.
3. Install the motor, tighten screws <1/10> using a torque of approximately 2 Nm.
Note the position of the motor!
4. Adjust the motor in relation to the gear in the gearbox.
5. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft.
6. Make sure there is very small play by turning axis 1 at least 45o.
7. Tighten screws <1/10> using a torque of 8.3 Nm 10%.
8. Connect the cabling.
9. Calibrate the robot as specified in section Calibration, M2000 on page 91.
Tightening torque
58
The motor attaching screws, item10:8.3 Nm 10%
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3HAC 021111-001
4 Repair
4.2.2 Changing the gearbox

Axis 1 gearbox is of the conventional type, manufactured with a high degree of precision and,
together with the gearboxes for axes 2 and 3, forms a complete unit.
The gearbox is not normally serviced or adjusted.
Note! If the gearbox on any of the axes 1, 2 or 3 is changed, the whole unit must
be changed.
See foldout 1 (6 for IRB 1400H) in the list of spare parts.
To dismantle
1. Remove the motors in axes 1, 2 and 3 as described in section Changing the motor
of axis 1 on page 58, section Changing the motor of axis 2 on page 63 and section
Changing the motor of axis 3 on page 68.
2. Remove the cabling and serial measuring boards according to section Changing
the cabling in axes 1, 2 and 3 on page 82 and section Changing serial measuring
boards on page 81.
3. Remove the tie rod as described in this chapter, section Changing the tie rod on
page 71.
4. Remove the parallel arm according to section Dismantling the parallel arm on
page 70.
5. Remove the balancing springs in accordance with section Dismantling the balancing springs on page 67 (not valid for IRB 1400H).
6. Dismantle the upper arm as described in section Dismantling the complete upper
arm on page 72.
7. Dismantle the lower arm according to section Dismantling the lower arm on page
65.
8. Place the remaining parts of the manipulator upside-down on a table or similar
surface and remove the bottom plate <1/5>. See Figure 20.
Make sure that the foot is stable.
Figure 20: How to Position the Foot when dismantling Axes 1, 2 and 3.
9. Undo screws <1/4>.

10.Separate the base from the gear unit.
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4 Repair
To assemble
1. Place a new gear unit on the table.

2. Raise the base.
3. Screw in the screws <1/4> together with their washers <1/3>. Tighten using a
torque of 68 Nm 10%.
4. Replace the bottom plate <1/5> using screws <1/7>.
5. Turn the foot.
6. Replace the lower arm as described in section Dismantling the lower arm on page
65.
7. Replace the parallel arm according to section Dismantling the parallel arm on
page 70.
8. Replace the upper arm as described in section Dismantling the complete upper
arm on page 72.
9. Replace the cabling in accordance with section Changing the cabling in axes 1, 2
and 3 on page 82 and section Changing serial measuring boards on page 81.
10.Replace the tie rod as described in section Changing the tie rod on page 71.
11.Replace the balancingd springs according to section Dismantling the balancing
springs on page 67 (not valid for IRB 1400H).
12.Calibrate the robot as described in section Calibration, M2000 on page 91.
Tightening
Torque
60
Screwed joint of base/gear unit, item <4>:68 Nm 10%
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3HAC 021111-001
4 Repair
4.2.3 Position indicator in axis 1 (optional)
4.2.3 Position indicator in axis 1 (optional)

To dismantle
1. Remove the flange plate <4/138>.

2. Loosen the connector R1.LS.
3. Dismantle the two limit switches <3/174>.
4. Loosen the cables from the switches.
5. Remove the cabling through the base.
To assemble
3HAC 021111-001
1. Assemble in the reverse order.
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61
4 Repair
4.2.4 Replacing the mechanical stop
4.2.4 Replacing the mechanical stop

See foldout 1 in the list of spare parts.
If the stop pins are bent, they must be replaced.
Remove the old stop pin.
68 1
Fit the new pin as illustrated in Figure 21 below.
Loctite 242 or 243
Figure 21: Fit the new Pin as illustrated.
62
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4 Repair
4.3: Axis 2
To dismantle
Lock the arm system before dismantling the motor; the brake is located in the motor.
5. Loosen the motor by unscrewing <1/10>. N.B! The oil will start to run out.
To assemble
2. Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP2 connector.
3. Install the motor, tighten screws <1/10> to a torque of approximately 2 Nm.
4. Adjust the motor in relation to the drive in the gearbox.
6. Make sure there is no play.
7. Tighten screws <1/10> to a torque of 8.3 Nm 10%.
8. Fill with oil. See section Oil in gears 1-4 on page 43.
10.Calibrate the robot as specified in section Calibration, M2000 on page 91.
Tightening torque
3HAC 021111-001
The motors fixing screws, item10: 8.3 Nm 10%
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63
4 Repair

Axis 2 gearbox is of a conventional type, manufactured with a high degree of precision and,
together with the gearbox for axes 1 and 3, forms a complete unit.
The gearbox is not normally serviced or adjusted.
Note! If the gearbox of any of the axes 1, 2 or 3 needs to be changed, the whole unit must
be changed.
To dismantle
64
See section Changing the gearbox on page 59.
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3HAC 021111-001
4 Repair
4.3.3 Dismantling the lower arm
4.3.3 Dismantling the lower arm

See foldouts 1 (6 for IRB 1400H) in the list of spare parts.
To dismantle
1. Remove the balancing springs as described in section Dismantling the balancing

2. Remove the cabling down to axis 1 according to section Cabling and serial measuring board on page 81.
3. Dismantle the upper arm as specified in section Dismantling the complete upper
arm on page 72.
4. Attach the crane to the lower arm.
5. Remove the parallel arm in accordance with section Dismantling the parallel arm
on page 70.
6. Loosen screws <1/13>.
7. Remove the lower arm.
To assemble
1. Transfer the damping element and calibration marking to the new lower arm.
2. Lift the lower arm into position.
3. Fix the lower arm to gear 2 using screws <1/13> and tighten them to a torque of
68 Nm 10%.
To prevent clicking during operation of the robot, grease the bearing seating of the parallel arm in the lower arm.
4. Replace the parallel arm as described in section Dismantling the parallel arm on
page 70.
5. Replace the upper arm as specified in section Dismantling the complete upper
arm on page 72.
6. Replace the balancing springs in accordance with section Dismantling the balancing springs on page 67 (not valid for IRB 1400H).
7. Replace the cabling as described in section Cabling and serial measuring board
on page 81.
8. Calibrate the robot according to section Calibration, M2000 on page 91.
Tightening torque
3HAC 021111-001
Screwed joint of lower arm/gear 2, item <13>:68 Nm 10%
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65
4 Repair
4.3.4 Changing the bearings in the upper arm
4.3.4 Changing the bearings in the upper arm

To dismantle
1. Loosen the upper bracket of the tie rod as described in section Changing the tie
rod on page 71.
2. Unscrew screws <13> which hold the parallel arm to gear 3.
3. Remove the bearings from the parallel arm.
To assemble
1. Fit new bearings to the parallel arm.

2. Replace the parallel arm using screws <13> and tighten to a torque of 68 Nm
10%.
3. Attach the upper bracket of the tie rod as specified in section Changing the tie rod
on page 71.
4. Calibrate the robot according to section Calibration, M2000 on page 91.
Tightening torque
66
Screwed joint of parallel arm/gear 3, pos. <13>:68 Nm 10%
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3HAC 021111-001
4 Repair
4.3.5 Dismantling the balancing springs
4.3.5 Dismantling the balancing springs

See foldouts 1 and 2 in the list of spare parts.
Note! Not valid for IRB 1400H.
To dismantle
1. Place the lower arm in a vertical position.

2. Loosen the locking nut <1/76>.
3. Release the spring using tool 3HAB 1214-6 and undo screw <1/13> at the same
time.
If the tool 3HAB 1214-6 is not available, but there are two persons, then the spring can
be released manually.
4. Unscrew <2/65> in the upper bracket of the spring.
5. Remove the springs.
To assemble
1. Before installing new springs, make sure that the distance between the attachment points is correct, see Figure 22. Lock the link heads using Loctite 242 or
243.
C C 377
Figure 22: Distance between the Attachment Points.
2. Lubricate the link heads with grease.

3. Attach the springs to the top bracket using screws <2/65> and tighten to a torque
of 68 Nm 10%.
4. Pull the springs down using tool 3HAB 1214-6 and attach screws <1/13>, together
with lifting lug <1/23> and washer <1/17>.
5. Attach the locking nut <1/76>.
Tightening torque
3HAC 021111-001
Screws of upper bracket, position <65>:68 Nm 10%.
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67
4 Repair
4.4: Axis 3
To dismantle

5. Loosen the motor by unscrewing <1/10>. N.B! The oil will start to run out.
To assemble
2. Release the brake, apply 24 V d.c. to terminals 7 and 8 on the 4.MP1 connector.
4. Adjust the motor in relation to the drive in the gearbox.
6. Make sure there is no play.
8. Fill with oil. See section Oil in gears 1-4 on page 43.
Tightening torque
68
The motors fixing screws, item 10:8.3 Nm 10%
Revision -
3HAC 021111-001
4 Repair

Axis 3s gearbox is of a conventional type, manufactured with a high degree of precision and,
together with the gearbox for axes 1 and 2, forms a complete unit.
The gearbox is not normally serviced are adjusted.
Note! If the gearbox of any of the axes 1, 2 or 3 needs to be changed,the whole unit must
be changed.
To dismantle
3HAC 021111-001
See this chapter, section Changing the gearbox on page 64.
Revision -
69
4 Repair
4.4.3 Dismantling the parallel arm
4.4.3 Dismantling the parallel arm

To dismantle
1. Loosen the upper bracket of the tie rod as described in this chapter, section
Changing the tie rod on page 71.
2. Unscrew screws <13> which fix the parallel arm to gear 3.
3. Remove the bearings from the parallel arm.
To assemble
1. Fit the bearings on the parallel arm.

2. Replace the parallel arm using screws <13> and tighten to a torque of
68 Nm 10%.
3. Attach the upper bracket of the tie rod according to section Changing the tie rod
on page 71.
Tightening torque
70
Screwed joint of parallel arm/gear 3, item <13>:68 Nm 10%
Revision -
3HAC 021111-001
4 Repair
4.4.4 Changing the tie rod
4.4.4 Changing the tie rod

To dismantle
Lock the upper arm in a horizontal position with the help of a crane or similar.
1. Unscrew screw <74>.
2. Undo the two screws for fixing the cabling bracket of the upper arm housing.
Fold back the cabling bracket.
3. Screw the screw <74> back into the shaft <71>.
4. Carefully knock the shaft out.
5. Remove housing <72>.
6. Unscrew <70> on the lower bracket.
7. Carefully tap the rod off the shaft.
8. Change the bearings.
To assemble
1. Fit bearings on the parallel arm.

2. Make sure you replace the rod the correct way up. See foldout 1 (1:1).
3. Install grommets: (3 x) <68> and (1 x) <75>.
Note! The grommet <75> is bevelled and must be inserted the right way up in the lower
bearing.
4. Place the lower bearing of the tie rod on the parallel arm.
5. Screw in screw <70> and its washer <69>. Lock using Loctite 242 or 243.
6. Replace shaft <71>. N.B! Do not forget the sleeve <72>.
7. Mount washer <73> and tighten the shaft using a temporary screw, M8x35.
8. Replace this screw by screw <74> and mount the cable bearer <163>.
Lock using Loctite 242 or 243.
3HAC 021111-001
Revision -
71
4 Repair
4.4.5 Dismantling the complete upper arm

To dismantle
Attach a crane to the upper arm.
1. Unscrew the upper bracket of the tie rod as specified in section Changing the tie
rod on page 71.
2. Loosen the connectors of the motors of axes 4, 5 and 6.
3. Disconnect the connection box from the motors.
4. Detach the balancing springs as described in section Dismantling the balancing
5. Undo the KM nuts <64>.
6. Remove washers <63> and shims <61-62> on the same side as axis 3.
7. Attach the withdrawing tool 3HAB 1259-1 and pull the axes off.
To assemble
1. Raise the upper arm into assembly position.

2. Install shaft spindles <59> (both sides), use two temporary screws M10x90.
3. Insert bearings <60> (both sides) using tool 3HAB 1200-1 and screws <65>.
4. Detach the tool and tighten the screws once more, only to prevent rotation of the
axis when the KM nut is tightened.
N.B! Assemble the same side as axis 2 first.
5. Mount two washers <63> and calibration washer <50>.
6. Tighten using the KM nut <64>.
7. Attach the measuring instrument 3HAB 1205-1 to the shaft spindle on axis 3.
N.B! If measuring instrument 3HAB 1205-1 is not available, you can use a micrometer
thickness gauge.
8. Hold the tool against the shoulder of the shaft spindle and measure the
dimension A. See Figure 23.
(If you are not using the measuring instrument, tighten using the KM nut and,
before measuring with the micrometer thickness gauge, then undo it again.)
72
Revision -
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4 Repair
Figure 23: Measuring the Shim Thickness when preloading the Bearing.
9. Make a note of the dimension A. Fit one washer <63> and shims <61-62>, and
using the micrometer, measure the thickness so that the total thickness is
0.10 - 0.20 mm more than the noted dimension A. This will result in a preloading
of the bearing of 0.10 - 0.20 mm.
10.Fit the shims and washer and tighten the KM nut <64>.
11.Replace the upper attachment of the tie rod as specified in section Changing the
tie rod on page 71.
12.Replace the balancing springs as described in section Dismantling the balancing
13.Reconnect the connection boxes and the cabling.
14.Calibrate the robot in accordance with section Calibration, M2000 on page 91.
15.Undo the KM-nut on the axis 2 side, just to be able to adjust the calibration
washer <50>.
16.If the old armhouse is mounted, adjust the calibration washer according to the
punch mark. If the armhouse is new adjust the washer according to Figure 24 and
make new punch marks for axes 3 and 4, according to section Calibration scales
and correct axis position on page 94.
3HAC 021111-001
Revision -
73
4 Repair
105o
Figure 24: Calibration Mark for Axis 3.
Tools pressing
tool for bearings:
3HAB 1200-1
74
Measuring instrument:
3HAB 1205-1
Withdrawing tool for shaft spindles:
3HAB 1259-1
Revision -
3HAC 021111-001
4 Repair
4.5.1 Changing the motor
4.5: Axis 4
4.5.1 Changing the motor
Position the arm system in such a way that the motor of axis 4 points upwards.
To dismantle

5. Loosen the motor by unscrewing <8/23>.
To assemble
2. Put O-ring <8/21> on the motor.
3. Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP4 connector.
5. Adjust the position of the motor in relation to the drive in the gearbox.
7. Make sure there is a small clearance.
8. Unscrew one screw at a time, apply Loctite 242 or 243 and tighten to a torque of
4.1 Nm 10%.
Tightening torque
The motors fixing screws, item <23>:4.1 Nm 10%
Tool
Crank tool for checking the play:
3HAC 021111-001
Revision -
3HAB 1201-1
75
4 Repair
4.5.2 Changing the intermediate gear including sealing

To dismantle
1. Dismantle the wrist as described in section Dismantling the wrist on page 85.
2. Dismantle the drive mechanism according to section Dismantling the complete
drive mechanism of axes 5 and 6 on page 86.
3. Dismantle the motor of axis 4 as specified in section Changing the motor on page
75.
4. Remove the cover <25>.
5. Undo screws <18> fixing the large drive gear <17> and dismantle it.
N.B! Put the shims in a safe place.
6. Undo screws <12>.
7. Push the intermediate gear out of the arm housing.
To assemble
1. Grease the seating of the arm housing to provide radial sealing.

2. Push the gear unit down into the arm housing.
3. Screw in screws <12> together with their washers <13> and pull the gear down.
4. Mount the drive gear <17> using screws <18> and tighten to a torque of
8.3 Nm 10%.
N.B! Do not forget to insert shims <14, 15, 16> under the drive gear.
5. Tighten screws <12> to a torque of approximately 5 Nm.
6. Bend the pinion towards the large drive gear and then rotate it around the tubular
shaft a couple of times so that the clearance in the gears can adjust itself in relation to the highest point of the large drive gear.
7. Then tighten screws <12> to a torque of 20 Nm 10%.
8. Check the clearance in relation to the tightening torque.
9. Replace the cover <25> using screws <26>. Use a drop of Loctite 242 or 243.
10.Position the manipulator so that the tubular shaft points upwards.
11.Fill (30 ml) oil into the gear of axis 4. See section Oil in gears 1-4 on page 43.
12.Install the motor of axis 4 in accordance with section Changing the motor on page
75.
13.Install drive mechanism <28> as described in section Dismantling the complete
14.Replace the wrist in accordance with section Dismantling the wrist on page 85.
76
Revision -
3HAC 021111-001
4 Repair
Tightening torque
3HAC 021111-001
Screws for the large drive gear, item <18>:
8.3 Nm 10%
Screws for the intermediate gear of axis 4, item <12>:
20 Nm 10%
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77
4 Repair
4.5.3 Dismantling the drive gear on the tubular shaft

To dismantle
2. Dismantle the drive mechanism in accordance with section Dismantling the complete drive mechanism of axes 5 and 6 on page 86.
3. Dismantle the motor of axis 4 as specified in section Changing the motor on page
75.
4. Remove the cover <25>.
5. Unscrew screws <12> that hold the intermediate gear in place.
6. Unscrew screws <18> that hold the large drive gear <17> and then dismantle it.
N.B! Put the shims from under the drive gear in a safe place.
To assemble
Shim between drive gear <17> and the rear bearing <3>.
Shim thickness = B - A + 0.05 mm, see Figure 25.
Figure 25: Measuring the Shim Thickness of the Drive Gear of Axis 4.
1. Install the drive gear using screws <18> and tighten to a torque of 8.3 Nm 10%.
N.B! Do not forget the shims.
2. Screw screw <19> and 2 washers <20> into the drive gear. Lock using Loctite 242
or 243.
3. Mount the intermediate gear according to section Changing the intermediate gear
including sealing on page 76.
4. Lubricate the drive gear with grease (30 g).
5. Install the motor of axis 4 as described in section Changing the motor on page 75.
6. Replace the cover <25> using screws <26>. Lock using a drop of Loctite 242 or
243.
78
Revision -
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4 Repair
7. Mount the drive mechanism as specified in section Dismantling the complete

8. Mount the wrist according to section Dismantling the wrist on page 85.
Tightening torque
3HAC 021111-001
Screws of drive gear, item <18>:
Revision -
8.3 Nm 10%
79
4 Repair
4.5.4 Dismantling the tubular shaft and changing bearings
4.5.4 Dismantling the tubular shaft and changing bearings

To dismantle
1. Dismantle the drive gear as described in section Dismantling the drive gear on the
tubular shaft on page 78.
2. Push out the tubular shaft.
To assemble
1. Fit a new bearing <3> on the tubular shaft using tool 6896 134-V.
2. Push the tube into the housing of the upper arm.
3. Insert the rear bearing <3> using tool 6896 134-JB.
4. Mount the drive gear in accordance with section Dismantling the drive gear on the
tubular shaft on page 78.
Tools
80
Pressing tool for front bearing:
6896 134-V
Pressing tool for rear bearing:
6896 134-JB
Revision -
3HAC 021111-001
4 Repair
4.6.1 Changing serial measuring boards
4.6: Cabling and serial measuring board

4.6.1 Changing serial measuring boards
To dismantle
1. Remove flange plate <138>.

2. Cut tie around bundle <144>.
3. Unscrew the serial measuring board <135> using screws <7>.
4. Remove the board and loosen the contacts.
To assemble
3HAC 021111-001
Revision -
81
4 Repair
4.6.2 Changing the cabling in axes 1, 2 and 3

To dismantle
1. Remove the cover of the motors.

3. Loosen connectors R1.MP, R2.FB1-3.
4. Cut tie around bundle and detach the cable brackets.
5. Detach the cable guides <3/104 and 105> and undo screws <3/149>.
6. Loosen the connectors in the motors.
7. Disconnect the connection boxes in the motors.
8. Feed the cabling up through the middle of axis 1.
To assemble
82
Revision -
3HAC 021111-001
4 Repair

See foldouts 2, 3 and 4 (6 for IRB 1400H) in the list of spare parts.
To dismantle
1. Remove the cover of the motors.

3. Loosen connectors R2.MP4-6 and R2.FB4-6, including customer connector
R1.CS (if there is one) and the air hose.
4. Detach the cable guides <3/104, 105>.
5. Loosen the cable brackets <3/149> between gears 2 and 3 and cut the tie around
them.
6. Feed the cabling and air hose up through axis 1.
7. Loosen the cable bracket on the lower arm and undo screws <3/147>.
8. Undo screw <2/74> which fixes the shaft of the tie rod.
9. Disconnect the connection boxes in the motors.
10.Loosen the remaining cable brackets and remove the cabling.
To assemble
3HAC 021111-001
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4 Repair
4.7: The wrist and axes 5 and 6

The wrist, which includes axes 5 and 6, is a complete unit, comprising drive units and gears.
It is of such a complex design that it is not normally serviced on-site, but should be sent to
ABB to be serviced.
ABB recommends its customers to carry out only the following servicing and repair work on
the wrist.
84
Grease the wrist according to the table in section Maintenance Intervals on page
42.
Revision -
3HAC 021111-001
4 Repair
4.7.1 Dismantling the wrist
4.7.1 Dismantling the wrist

See foldouts 1 (6 for IRB 1400H) and 9 in the list of spare parts.
To dismantle
1. Remove the 2 plastic plugs on the rear of the wrist.

2. Release the brake in axes 5 and 6.
3. Rotate axes 5 and 6 so that you can see screws <9/15> in the clamping sleeve
through the hole.
4. Disconnect the clamping sleeve.
5. Undo screws <1/53> and remove the wrist.
To assemble
1. Mount the wrist, tighten screws <1/53> to a torque of 8.3 Nm 10%.

Note! The grease nipple on the tilt house should be pointing against the base
when the axis 4 is in the calibration position.
2. Screw the clamping sleeves together using screws <9/15>.
3. Replace the plastic plugs.
4. Calibrate the robot as described in section Calibration, M2000 on page 91.
Tightening torque
3HAC 021111-001
Screwed joint of wrist/tubular shaft, item <1/53>:8.3 Nm 10%
Revision -
85
4 Repair
4.7.2 Dismantling the complete drive mechanism of axes 5 and 6
4.7.2 Dismantling the complete drive mechanism of axes 5 and 6

To dismantle
1. Dismantle the wrist according to section Dismantling the wrist on page 85.
2. Loosen the connectors on the motors of axes 5 and 6.
3. Undo screws <8/29>.
4. Squeeze the drive shafts (<9/1>) together at the tip of the tubular shaft, in order
that they can pass through the tube.
5. Pull out the complete drive mechanism of axes 5 and 6.
To assemble
1. Install the drive mechanism in the tubular shaft.

3. Insert the cabling.
4. Mount the wrist as described in section Dismantling the wrist on page 85.
Tightening torque
86
Screwed joint of the drive mechanism, item <8/29>:8.3 Nm 10%
Revision -
3HAC 021111-001
4 Repair
4.7.3 Changing the motor or driving belt of axes 5 and 6
4.7.3 Changing the motor or driving belt of axes 5 and 6

To dismantle
2. Dismantle the drive mechanism according to section Dismantling the complete
3. Undo screws <9> and remove the appropriate motor.
4. If the driving belt is to be changed, both motors must be removed.
5. Undo screws <9> and remove plate <7>.
To assemble
1. Install the driving belts.

2. Mount the plate <7> using screws <9>.
N.B! Do not forget the nuts of the motors.
3. Install the motors.
4. Push the motors in sideways to tension the belts. Use tool 3HAA 7601-050.
Tighten screws <9> to a torque of 4.1 Nm.
5. Rotate the drive shafts. Check the tension on the belt.
6. Install the drive mechanism as described in section Dismantling the complete
7. Mount the wrist according to section Dismantling the wrist on page 85.
Tightening torque
Screws for motors and plate, item <9>:
4.1 Nm.
Tool
To adjust the belt tension:
3HAC 021111-001
Revision -
3HAA 7601-050
87
4 Repair
4.7.4 Measuring play in axes 5 and 6
4.7.4 Measuring play in axes 5 and 6
Axis 5
Axis 4 shall be turned 90o. The maximum accepted play in axis 5 is 4.7 arc.minutes when
loading axis 5 with a moment of 4.8 Nm in one direction, unloading to 0.24 Nm and start measuring the play, loading in the other direction with 4.8 Nm unloading to 0.24 Nm and reading
the play. This correspond to play of 0.27 mm on a radius of 200 mm when the load is F=40
N and 2 N on radius 120 mm. See Figure 26.
120
35
F
200
Figure 26: Measuring Play in Axis 5.
Axis 6
The maximum accepted play in axis 6 is 12.8 arc.minutes when loading axis 6 with a moment
of 4.2 Nm in one direction, unloading to 0.2 Nm and start measuring the play, loading in the
other direction with 4.2 Nm unloading to 0.2 Nm and reading the play. This correspond to a
play of 0.37 mm on a radius of 100 mm when the load is F=42 N and 2 N. See Figure 27.
100
Figure 27: Measuring Play in Axis 6.
88
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4 Repair
4.8.1 General
4.8: Motor units

4.8.1 General
General
Each axis of the manipulator has its own motor unit, comprising:
A synchronous motor
A brake (built into the motor)
A feedback device.
There are a total of six motors mounted in the manipulator.

The power and signal cables are run to the respective motor from the cable connector points
on the manipulator. The cables are connected to the motor units by connectors.
The drive shaft of the electric motor forms a part of the gearbox of the manipulator axis. A
brake, operated electromagnetically, is mounted on the rear end of the motor shaft and a pinion is mounted on its drive end. The brake releases when power is supplied to the electromagnets.
N.B!
There is a feedback device mounted on each motor unit. The device is installed by the supplier
of the motor and should never be removed from the motor. The motor need never be commutated.
The commutation value of the motors is: 1.570800.
The motor, resolver and brakes are regarded as one complete unit.
3HAC 021111-001
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4 Repair
4.8.1 General
90
Revision -
3HAC 021111-001
5 Calibration, M2000
5.0.1 Introduction
5.0.1 Introduction
Calibration
methods
This chapter details how to calibrate the robot with the Wyler calibration equipment, using
Levelmeter 2000, when the robot is part of an M2000 robot system (S4Cplus controller).
The robot can also be calibrated with the Calibration Pendulum equipment, as detailed in the
Calibration Pendulum Instruction, enclosed with the Pendulum toolkit.
When to calibrate
The system must be calibrated if any of the below occurs.
Changed resolver
values
Calibrate the measurement system carefully as detailed in section Calibration on page 103 if
any of the resolver values have changed. This may occur when parts affecting the calibration
position are replaced on the robot.
Contents of the
revolution counter
memory are lost
Calibrate the system roughly as detailed in section Updating the revolution counters on page
121 if the contents of the revolution counter memory are lost. This may occur when:
3HAC 021111-001
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
Revision -
91
5.1.1 How to calibrate the robot system
5.1: Overview
5.1.1 How to calibrate the robot system
General
This section provides an overview of the procedures to perform when calibrating the robot
system. Many of the steps in this overview are detailed in other sections to which references
are given.
Method -Wyler
Calibration
The calibration procedure with Wyler equipment may be performed with either one or two
sensors. The procedure detailed here is performed with only one sensor and may be described
as checking an pre-adjusted sensor, trying to obtain the same measurement value on every
axis as when adjusted at the reference plane.
All article numbers of relevant equipment are specified in their instructions respectively.
Overview,
calibration
Step
Additional
information
92
Action
Note
1.
Check that all required hardware is available for calibrating the robot.
Required hardware is specified in the

calibrating procedures for each axis.
2.
Manually run the robot axes to a position

close to the correct calibration position.
Use the calibration scales fitted to each

robot axis to locate this position. These
are shown in the section Calibration
scales and correct axis position on
page 94.
3.
Initialize the Levelmeter.
Detailed in section Initialization of Levelmeter 2000 on page 101.
4.
Start the calibration procedure on the TPU. Detailed in section Fine calibration procedure on TPU on page 115.
5.
Calibrate each axis.
6.
Verify that the calibration was successfully Detailed in section Post calibration procarried out.
cedure on page 123.
Detailed in each axis calibration

instruction.
In addition to the basic calibration procedure detailed above, a number of calibration related
actions may be performed:
Action
Detailed in section:
How to update the robot revolution counter without performing a complete calibration.
Updating the revolution counters

on page 121
How to manually check the current calibration position.
Checking the calibration position

on page 97
Revision -
3HAC 021111-001
5.1.2 Calibration, prerequisites
5.1.2 Calibration, prerequisites
Peripheral
equipment
The robot must be free from any peripheral equipment during calibration. Fitted tools and
similar will cause erroneous calibration positions.
Calibration order
The axes must be adjusted in increasing sequence, i.e. 1 - 2 - 3 - 4 - 5 - 6.
Location of
sensors
The positions where the calibration sensor and reference sensor should be fitted during calibration, are specified in Positions and directions of sensor on page 99.
3HAC 021111-001
Revision -
93
5.2.1 Calibration scales and correct axis position
5.2: Reference information

Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.
Safety
information
Read the safety information below.
If work must be carried out within the robots work envelope, the following points must be
observed:
94
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 19.
Revision -
3HAC 021111-001
Calibration
scales, IRB 1400
The illustration below shows the calibration scale positions:
en0200000272
3HAC 021111-001
Revision -
95
5.2.2 Directions for all axes
5.2.2 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!
xx0200000089
96
Revision -
3HAC 021111-001
5.2.3 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 the program CALxxxx in the system software (xxxx signifying the robot type;
IRB xxxx)
Using the Jogging window on the teach pendant
Using the program CALxxxx in

the system
software
Step
Action
Button
1.
Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx in the system and follow the instructions displayed on the teach pendant.
2.
Switch to MOTORS OFF when the robot stops.

Check that the calibration marks for that particular
axis align correctly. If they do not, update the revolution counters.
3.
Check that resolver offset values in the system

parameters match those on the parameter disk delivered with the robot or those established when calibrating the robot (after a repair, etc).
Calibration marks are shown

in section Calibration scales
and correct axis position on
page 94.
Detailed in section Updating
the revolution counters on
page 121.
Using the Jogging window on

the teach pendant
Step
1.
Action
Illustration
Open the Jogging window.
xx0100000195
2.
Choose running axis-by-axis.
xx0100000196
3HAC 021111-001
Revision -
97
Step
98
Action
Illustration
3.
Manually run the robot axis to a position where the

resolver offset value read, is equal to zero.
4.
Check that the calibration marks for that particular

Shown in section Calibration
axis align correctly. If they do not, update the revolu- scales and correct axis position counters!
tion on page 94.
Detailed in section Updating
the revolution counters on
page 121.
Revision -
3HAC 021111-001
5.2.4 Positions and directions of sensor
General
This section details the mounting positions and directions for the
reference sensor
calibration sensor
When calibrating an axis with only one sensor, the sensor must first be positioned at the base
of the manipulator in order to create reference values. This is further detailed in section Resetting of Levelmeter 2000 and sensor on page 117. These reference values are then used to
calibrate the axes of the manipulator.
The reference sensor and the calibration sensor is consequently the same sensor used at different locations.
When using the sensor as a reference at the base, it is fitted to a sensor fixture together with
a sensor plate, as shown in the figure below. The sensor has different directions, depending
on which axis is calibrated. The directions are shown in the figure below.
Calibration and
reference sensor
position
The calibration sensor is positioned and aligned on the axes as shown in the figure below.
Notice the different directions of the sensor when fitted to the reference plane, depending on
which axis is currently calibrated!
xx0400001019
3HAC 021111-001
Axis 2 sensor
Axis 3 sensor
Axis 4 sensor
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99
100
Axis 5 sensor
Axis 6 sensor
Direction for sensor at reference plane, axes 2, 3 and 5
Direction for sensor at reference plane, axes 4 and 6
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3HAC 021111-001
5.2.5 Initialization of Levelmeter 2000
Overview
Whenever Levelmeter 2000 is used for calibrating the robot, the equipment must first be
initialized as detailed in this section.
Shown below is an outline of how to initialize the Levelmeter 2000. Detailed procedures are
given further down.
1. Select the correct filter type, as detailed in Levelmeter 2000 on page 101.
2. Set the measuring unit, as detailed in Measuring units on page 102.
3. Install sensor, as detailed in Installation of sensor on page 102.
4. Calibrate the robot, as detailed in the instruction for each axis respectively, in the section Calibration on page 103!
Levelmeter 2000
The Levelmeter 2000 is shown for reference below:
xx0200000083
Measuring unit
Selection pointer
Sensor connection
Select filter type

Step
3HAC 021111-001
Action
Info/Illustration
1.
Press ON/MODE until the dot flashes under FILTER . Shown in the figure Levelmeter 2000 on page 101!
2.
Press ENTER.
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101
Step
Action
Info/Illustration
3.
The standard filter type no. 5 flashes.
4.
If type 5 does not flash, press ZERO/SELECT to

select filter type 5 and press ENTER.
Default setting is filter type 5.
Measuring units
Step
Action
Info/Illustration
1.
Press ON/MODE until the dot flashes under UNIT .
2.
Press ENTER.
3.
Press ZERO/SELECT until mm/m flashes.

Two decimals (0.00) are shown on the display
4.
Press ENTER.
Shown in the figure Levelmeter 2000 on page 101!
Installation of
sensor
Step
Result
102
Action
Info/Illustration
1.
Connect the sensor to the Sensor connection point.
2.
Press ON/MODE .
3.
Press ON/MODE until the dot flashes under SENSOR .
4.
Press ENTER.
5.
Press ZERO/SELECT until a flashing "A" is shown.
6.
Press ENTER.
Wait until the "A" flashes again.
7.
Press ENTER.
Shown in the figure Levelmeter 2000 on page 101!
The Levelmeter 2000 is now initialized and ready for service.
Revision -
3HAC 021111-001
5.3.1 Calibration, axis 1
5.3: Calibration
Calibration of
axis 1
The special calibration equipment is fitted to the base of the manipulator as shown in the
figure below.
xx0400001018
Guide pin in gearbox
Calibration tool
Measuring pin, axis 1
Required
equipment
3HAC 021111-001
Equipment, etc.
Art. no .
Note
Isopropanol
1177 1012-208
Used to clean the reference surface.
Calibration tool, axis 1
3HAB 1378-1
Measuring pin, axis 1
6808 0011-GR
Revision -
103
Calibration, axis 1
The procedure below details how to perform the actual calibration of axis 1 using the calibration equipment specified in Required equipment.
Step
104
Action
Note
1.
Move the robot to its calibration position corresponding to the calibration scales.
Detailed in section Calibration

scales and correct axis position
on page 94.
2.
Remove the cover plate from the reference sur- Art. no. is specified in Required
face on the base of the manipulator.
equipment on page 103.
Clean the surface with isopropanol and deburr it.
3.
Fit the calibration tool, axis 1 on the guide pin

underneath the gearbox.
Art. no. is specified in Required

Shown in the figure Calibration of
axis 1 on page 103.
4.
Release the brakes and move the manipulator

manually so that the measuring pin can be
placed in the guide hole on the base.

5.
Update only axis 1, using the TPU.
Detailed in section Fine calibration procedure on TPU on page

115.
6.
Remove the calibration tool for axis 1.
7.
Refit the cover plate to the reference surface on

the base of the manipulator, if no other calibration is to be performed.
Revision -
3HAC 021111-001
5.3.2. Calibration, axis 2
General
This section details how to perform the actual fine calibration of axis 2 using the Wyler calibration equipment.
Required
equipment
Equipment
Art. no.
Note
Levelmeter 2000 calibration kit

with one sensor
6369 901-347
Includes one sensor.
Sensor plate
3HAC 0392-1
One sensor plate is required for each

sensor!
Angle bracket
6808 0011-LP
For calibration sensor on manipulator

lower arm.
Isopropanol
1177 1012-108
For cleaning the attachment points.
Other tools and procedures may

be required. See references to
these procedures in the stepby-step instructions below.
These procedures include references to

the tools required.
TIP!
Lock the axes previous to the one calibrated to minimize the risk of accidentally moving other
axes! In case of accidental movement of previous axes, the calibration procedure must be
restarted from the moved axis and continued in increasing sequence!
Procedure
Step
3HAC 021111-001
Action
Illustration
1.
Reset the levelmeter and the sensor for calibration Detailed in section Resetting of
of axis 2.
Levelmeter 2000 and sensor on
page 117.
2.
Clean the calibration surface with isopropanol.

equipment on page 105!
3.
Fit the angle bracket on the lower arm.

Adjust the angle of the bracket to make it level.

4.
Fit the calibration sensor together with the sensor Shown in section Positions and
plate on the angle bracket on axis 2.
directions of sensor on page 99!
Carefully tighten the securing screws with approximately same tightening torque that used at the
reference plane!
Revision -
105
Step
5.
Action
Illustration
Manually run axis 2 in with the joystick to the cor- Correct measurement on the
rect position as indicated by the levelmeter.
levelmeter:
0 0.40 mm/m
Tip!
Reduce the jogging velocity in order to easily position the axis as close to zero as possible!
106
6.
Update only axis 2.
7.
Remove the sensor.
8.
Refit the cover plate on the calibration surface on

the manipulator lower arm. Refit also the cover
plate on the reference surface at the base if no
further calibration is performed.
9.
Check the calibration according to section Post

calibration procedure on page 123 or continue
with calibration of next axis.
Revision -

115.
3HAC 021111-001
General
Required
equipment
Equipment
Art. no.
Info

with one sensor
6369 901-347
Sensor plate
3HAC 0392-1

sensor.
Turning disk fixture
6808 0011-GU
For fitting the calibration sensor plate

to the sync adapter.
Isopropanol
1177 1012-108
Other tools and procedures

may be required. See references to these procedures in
the step-by-step instructions
below.
These procedures include references

to the tools required.
TIP!
Procedure
Step
3HAC 021111-001
Action
Illustration/Info
1.
Clean the manipulator turning disk with isopropanol.

2.
Fit the turning disk fixture (incl. guide pin) on the

turning disk.

3.
Turn the tool clockwise against the pin at the

same time as the screws are tightened.
4.
Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx (xxxx=robot model,

e.g. 7600) in the system and select Calib: CAL3.
The robot moves to the position for calibration of
axis 3.
5.
Reset the levelmeter with correct orientation of

the sensor for calibration of axis 3.
Revision -
Detailed in section Resetting of

page 117.
107
Step
Action
Illustration/Info
6.
Fit the calibration sensor unit (sensor and plate)

on the turning disk fixture.
Carefully tighten the securing screws with
approximately same tightening torque that used
at the reference plane.
Shown in the section Positions

and directions of sensor on page
99!
7.
Manually run axis 3 in with the joystick to the cor- Correct measurement on the
rect position as indicated by the levelmeter.
levelmeter:
0 0.40 mm/m
Tip!
Reduce the jogging velocity in order to easily

position the axis as close to zero as possible!
8.
Update only axis 3.
9.
Remove the sensor.

115.
10. Check the calibration according to section Post

calibration procedure on page 123 or continue
with calibration of next axis.
11. Refit the cover plate on the reference surface on
the base if no further calibration is performed.
108
Revision -
3HAC 021111-001
General
Required
equipment
Equipment
Art. no.
Info
Levelmeter 2000 calibration

kit with one sensor
6369 901-347
Sensor plate
3HAC 0392-1

sensor.
6808 0011-GU
For fitting the calibration sensor plate to

the sync adapter.
Isopropanol
1177 1012-108

below.

the tools required.
TIP!
Procedure
Step
3HAC 021111-001
Action
Illustration
1.
Clean the manipulator turning disk with isopropanol Art. no. is specified in Required
.
2.
Fit the turning disk fixture (incl. pin) on the turning

disk.
3.
Turn the tool clockwise against the pin at the same

time as the screws are tightened.
4.
Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx (xxxx=robot model, e.g.

7600) in the system and select Calib: CAL4A.
The robot moves to the position for calibration of
axis 4.
5.
Reset the levelmeter with correct orientation of the Detailed in section Resetting of
sensor for calibration of axis 4.
Levelmeter 2000 and sensor
on page 117.
Revision -

109
Step
Action
Illustration
6.
Fit the calibration sensor unit (sensor and plate) on Shown in the section Positions
the turning disk fixture.
and directions of sensor on
Carefully tighten the securing screws with approxi- page 99!
mately same tightening torque that used at the reference plane.
7.
Manually run axis 4 in with the joystick to the correct Correct measurement on the
position as indicated by the levelmeter.
levelmeter:
0 0.80 mm/m
Tip!
8.
Update only axis 4.
9.
Remove the sensor.
Detailed in section Fine calibration procedure on TPU on

page 115.
10. Select Calib: CAL4B.

The axis 4 moves 90, to a correct position.
11. Update only axis 4.

page 115.
12. Check the calibration according to section Post calibration procedure on page 123 or continue with
calibration of next axis.
13. Refit the cover plate on the reference surface at the
base if no further calibration is performed.
110
Revision -
3HAC 021111-001
General
Required
equipment
Equipment
Art. no.
Levelmeter 2000 calibration

kit with one sensor
6369 901-347
Sensor plate
3HAC 0392-1

sensor.
6808 0011-GU
For fitting the calibration sensor plate to

the sync adapter.
Isopropanol
1177 1012-108

below.
Info

the tools required.
TIP!
Procedure
Step
3HAC 021111-001
Action
Illustration
1.
Clean the manipulator turning disk with isopropanol Art. no. is specified in Required
.
2.
Fit the turning disk fixture (incl. pin) on the turning

disk.
3.
Turn the tool clockwise against the pin at the same

time as the screws are tightened.
4.
Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx (xxxx=robot model, e.g.

7600) in the system and select Calib: CAL5.
The robot will now move to the position for calibration of axis 5.
5.
Reset the levelmeter with correct orientation of the Detailed in section Resetting of
sensor for calibration of axis 5.
Levelmeter 2000 and sensor
on page 117.
6.
Fit the calibration sensor on the turning disk fixture. Shown in the section Positions
Carefully tighten the securing screws with approxi- and directions of sensor on
mately same tightening torque that used at the ref- page 99!
erence plane.
Revision -

111
Step
7.
Action
Illustration
Manually run axis 5 in with the joystick to the correct Correct measurement on the
position as indicated by the levelmeter.
levelmeter:
0 0.80 mm/m
Tip!
8.
Update only axis 5.
9.
Remove the sensor.

page 115.
10. Check the calibration according to section Post calibration procedure on page 123 or continue with
calibration of next axis.
11. Refit the cover plate on the reference surface at the
base if no further calibration is performed.
112
Revision -
3HAC 021111-001
General
Required
equipment
Equipment
Art. no.

with one sensor
6369 901-347
Sensor plate
3HAC 0392-1

sensor.
6808 0011-GU
For fitting the calibration sensor plate

to the sync adapter.
Isopropanol
1177 1012-108
Other tools and procedures may

be required. See references to
these procedures in the stepby-step instructions below.
Info
These procedures include references

to the tools required.
TIP!
Procedure
Step
Action
Illustration
1.
Calibrate axis 5.
Detailed in section Calibration,

axis 5 on page 111.
2.
Reset the levelmeter with correct orientation of Detailed in section Resetting of

the sensor for calibration of axis 6.
page 117.
3.
Fit the calibration sensor unit (sensor and plate) Shown in section Positions and
on the turning disk fixture.
directions of sensor on page 99!
Carefully tighten the securing screws with
approximately same tightening torque that used
at the reference plane.
4.
Manually run axis 6 in with the joystick to the

correct position as indicated by the levelmeter.
0 0.80 mm/m
Tip!
Reduce the jogging velocity in order to easily

position the axis as close to zero as possible!
3HAC 021111-001
Revision -
113
Step
114
Action
Illustration
5.
Update only axis 6.
6.
Remove the sensor.
7.
Check the calibration according to section Post

calibration procedure on page 123.
8.
Refit the cover plate on the reference surface at

the base.
Revision -
Detailed in section Fine calibration

procedure on TPU on page 115.
3HAC 021111-001
5.3.7 Fine calibration procedure on TPU
General
This section details how to use the Teach Pendant Unit (TPU) when performing a fine calibration of the robot. The method of fitting the calibration equipment to each axis is detailed
in the calibration instruction for the axis.
Procedure
Step
1.
Action
Note/Illustration
Press the button "Miscellaneous".
xx0100000194
2.
Select the Service window

by pressing ENTER.
3.
Select Calibration from

the View menu. The Calibration window appears.
If multiple units are connected to the robot, they will
be listed in the window.
xx0100000200
xx0100000201
The calibration status can be any of the following:

Synchronized: all axes are calibrated and their
positions are known. The unit is ready for use.
Revolution Counter not updated: all axes are
fine-calibrated but one (or more) of the axes
has a counter that is NOT updated. This axis,
or these axes, must therefore be updated as
detailed in section Updating the revolution
counters on page 121.
Not calibrated: one (or more) of the axes is
NOT fine-calibrated. This axis, or these axes,
must therefore be fine-calibrated as detailed
below and in the calibration instructions for
each axis.
3HAC 021111-001
Revision -
115
Step
Action
Note/Illustration
4.
Select the desired unit and

choose Fine Calibrate
from the Calib menu. A
Warning window appears.
5.
Move the desired robot axis

according to the calibration
procedure for current axis.
These procedures are found
in section Calibration on
page 103.
Press OK. The Fine Calibrate window appears.
xx0100000203
xx0100000204
116
6.
Select the desired axis and

press Incl to include it (it
will be marked with an x) or
press All to select all axes.
7.
Press OK when all axes that

are to be updated are
marked with an x.
CANCEL returns to the Calibration window.
8.
Press OK again to confirm

and start the update.
CANCEL returns to the Fine
Calibration window.
An alert box is displayed during calibration. The Status
window appears when the
fine calibration is complete.
The revolution counters are
always updated at the same
time as the calibration is performed.
Revision -
3HAC 021111-001
5.3.8 Resetting of Levelmeter 2000 and sensor
General
The equipment must first be reset before calibrating each axis.

This section details how to reset the Levelmeter 2000 and make the one sensor ready for
calibration.
Levelmeter 2000
The Levelmeter 2000 is shown for reference below:
xx0200000083
3HAC 021111-001
Measuring unit
Selection pointer
Sensor connection
Revision -
117
Sensor mounted
on fixture
When using the sensor as a reference sensor it is fitted to the sensor fixture, together with a
sensor plate, as shown below.
See the section Positions and directions of sensor on page 99 for actual positioning and orientation of the fixture and the sensor, since the direction of the sensor differs depending on
which axis is calibrated.
xx0100000207
Reference sensor, fitted to the sensor plate (actual direction differs)
Sensor fixture, fitted on manipulator base
Attachment screws, sensor plate
Required
equipment
118
Equipment
Art. no.
Note
Levelmeter, one sensor
6369 901-347
Sensor plate
3HAC 0392-1
Sensor fixture
6808 0011-GM
Isopropanol
1177 1012-108
Revision -
For cleaning the sensor fixture.
3HAC 021111-001
NOTE!
Note!
Always secure the sensor to the sensor fixture using screws and with approximately the same
torque each time!
NOTE!
Note!
Always fit the sensor in the same direction when resetting it as when performing the calibration for each axis!
NOTE!
Note!
Always reset the sensor when using it in a new direction!
Resetting
Step
3HAC 021111-001
Action
Info/Illustration
1.
If the sensor and the sensor plate are sepa- Art. no. is specified in Required
rate, fit them together by first cleaning the
attachment area on the sensor plate with isopropanol and then fitting the sensor to it.
Handle the sensor plate and the sensor as a
complete unit when fitting it to and moving it
between the reference point and the different
axes.
2.
Make sure the Levelmeter is initialized

according to section Initialization of Levelmeter 2000 on page 101.
3.
Remove the cover plate on the reference sur- Shown in the section Positions and
face on the manipulator base.
directions of sensor on page 99.
4.
Clean the area where the sensor fixture is fitted with isopropanol .
5.
Fit the sensor fixture on the reference surface Art. no. is specified in Required
on the manipulator base.
Orientation is specified in section
Positions and directions of sensor on
page 99!
6.
Clean the sensor plate attachment area on

the fixture with isopropanol.
7.
Fit the sensor unit (sensor plate and sensor) Correct direction is shown in Posion to the sensor fixture and connect the sen- tions and directions of sensor on
sor to the Levelmeter 2000.
page 99.
Connection is shown in the figure
Levelmeter 2000 on page 117.
8.
Press ON/MODE on the Levelmeter 2000

until the dot flashes under REL ZERO .
9.
Press ENTER.
Revision -
Shown in the figure Levelmeter 2000

on page 117!
119
Step
Action
Info/Illustration
10. Wait until + or - flashes.

11. Press HOLD .
12. Wait until + or - flashes.
13. Press ENTER.
Result
120
The Levelmeter 2000 and the one sensor is now reset and ready for service. When moving
the sensor and the sensor plate to different axes, move it as a complete unit.
Revision -
3HAC 021111-001
5.3.9 Updating the revolution counters
Manually running
the manipulator
to the calibration
position
This section details the first step when updating the revolution counter; manually running the
manipulator to the calibration position.
Step
Storing the
revolution
counter setting
Action
Illustration
1.
Select axis-by-axis motion mode.
2.
Press the enabling device on the teach pendant and, Shown in section Calibration
using the joystick, move the robot manually so that
scales and correct axis posithe calibration marks lie within the tolerance zone.
tion on page 94.
3.
Note that axis 6 does not have any mechanical stop

and can thus be calibrated at the wrong faceplate revolution. Do not operate axis 6 manually before the
robot has been calibrated.
4.
When all axes are positioned as above, store the revolution counter settings using the Teach Pendant Unit
as detailed below:
This section details the second step when updating the revolution counter; storing the revolution counter setting.
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 very carefully after each update!
Step
1.
Action
Illustration
Press the button "Miscellaneous".
xx0100000194
2.
Select the Service window by pressing ENTER.
xx0100000200
3HAC 021111-001
Revision -
121
Step
Action
Illustration
3.
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.
4.
Select the desired unit and

choose Rev Counter
Update from the Calib
menu.
The Revolution Counter
Update window appears.
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.
6.
Press OK when all axes

that are to be updated are
marked with an x.
CANCEL returns to the
Calibration window.
7.
Press OK again to confirm

and start the update.
CANCEL returns to the
Revolution Counter
Update window.
8.
At this point, it is recomNot required.

mended that the revolution
counter values are saved
to a diskette.
9.
Recheck the calibration

position.
xx0100000201
xx0100000202
122
Revision -
Detailed in section Checking the calibration position on

page 97
3HAC 021111-001
5.4.1 Post calibration procedure
5.4: After calibration

General
Perform the following procedure after calibrating any manipulator axes. The procedure is
intended to verify that all calibration positions are correct.
Procedure
Step
3HAC 021111-001
Action
Illustration
1.
Run the calibration home position program twice.

Do not change the position of the manipulator axes
after running the program!
2.
Check the calibration positions.

Detailed in section CalibraIf the axes are outside the tolerance, start the calibration scales and correct axis
position on page 94.
tion procedure from the beginning, in increasing
sequence of the axes.
3.
Repeat the check as above.
4.
Adjust the calibration marks when the calibration is

done.
5.
The system parameters will be saved to the storage

memory at power off.
6.
Change the values on a new label and stick it on top

of the label located
underneath the flange plate on the base.
7.
Remove any calibration equipment from the manipulator.
Revision -
Detailed in section Checking

the calibration position on
page 97.
Shown in section Calibration

scales and correct axis position on page 94.
123
124
Revision -
3HAC 021111-001
6.0.1 Introduction
6.0.1 Introduction
Calibration
3HAC 021111-001
This chapter will describe how to calibrate the robot with the Wyler calibration equipment,
using Levelmeter 2000, when the robot is part of an M2004 robot system (IRC5 controller).
This chapter will be completed in the upcoming revision of the manual.
Revision -
125
6.0.1 Introduction
126
Revision -
3HAC 021111-001
7 Alternative calibration
7.0.1 Alternative calibration position
7: Alternative calibration
7.0.1 Alternative calibration position
General
The manipulator may be calibrated in alternative positions.

The regular calibration instructions detailed for each axis are intended for calibration position 0, i.e. the normal position. Calibration instructions for alternative positions are detailed
in Alternative calibrating on page 128.
Illustration
The illustration shows the available calibrating positions of a suspended robot.
xx0400001020
3HAC 021111-001
Calibration program Normal, calibration position 0 (axes 2 and 3)
Calibration program Hanging, calibration position -1.570796 (axes 2 and 3)
Revision -
127
7.0.2 Alternative calibrating
7.0.2 Alternative calibrating
General
The manipulator may be calibrated in any of three positions, shown in Alternative calibration position on page 127.
Procedure
Step
128
Action
Illustration
1.
Calibrate the robot in position 0 for all axes.

Set an alternative calibration position before installation if the final
installation makes it impossible to reach the calibration 0 position.
2.
Run the calibration program CALxxx in the system\SYSTEM\UTILITY\SERVICE\CALIBRAT\.

(xxx = robot version, e.g. CAL1400)
3.
Select Normal position, and check the calibration marks for each
axis.
4.
Run the calibration program again and select the desired calibration position (Hanging) as shown in Alternative calibration position
on page 127.
5.
Change to the new calibration offset, as detailed in New calibration

offset on page 130.
6.
Note the new calibration offset on the label, located under the
flange plate on the base.
The new calibration offset values can be found as detailed in
Retrieving offset values on page 131.
7.
Change to the new calibration position as detailed in New calibration position on page 129.
8.
Restart the robot by selecting Restart from the File menu.
9.
Mark the new calibration positions for axes 2 and 3, with the punch
marker.
10.
The system parameters will be saved to the storage memory at

power off.
Revision -
3HAC 021111-001
7.0.3 New calibration position
7.0.3 New calibration position
Procedure
Use these instructions to change to a new calibration position for axis 1 during definition of
a new calibration position.
Step
1.
Action
Illustration
Press the "Miscellaneous" button
xx0100000194
2.
Select the System parameters window by pressing ENTER.
xx0100000200.
3HAC 021111-001
3.
Select Manipulator from the Topics menu.
4.
Select Arm from the Types menu.
5.
Select axes 2 and 3.
6.
Change Cal pos to -1.570796.

The angle is measured in radians as shown in Alternative calibration position on page 127.
Revision -
129
7.0.4 New calibration offset
7.0.4 New calibration offset
Procedure
Use these instructions when changing to a new calibration offset for axis 1 during definition
of a new calibration position.
Step
1.
Action
Illustration
Press the "Miscellaneous" button.
xx0100000194
2.
Select the Service

window by pressing
ENTER.
3.
Select Calibration
from the View menu.
The calibration window appears.
4.
Select Calibrate from

the Calib menu.
5.
Select axes 2 and 3.
6.
Confirm by pressing
OK twice.
xx0100000200
xx0100000201
130
Revision -
3HAC 021111-001
7.0.5 Retrieving offset values
Procedure
Use these instructions when retrieving new offset values for axis 1 during definition of a new
calibration position.
Step
1.
Action
Illustration
Press the "Miscellaneous" button.
xx0100000194
2.
Select the System parameters window by pressing

ENTER.
xx0100000200
3.
Select Motor from the Types menu.
4.
Select axes 2 and 3 and press ENTER.
5.
Note the Cal offset value.
xx0100000200
3HAC 021111-001
Revision -
131
132
Revision -
3HAC 021111-001
Index
C
Calibration position, 121
R
Revolution counters, 121
U
Updating revolution counters, 121
3HAC 021111-001
133
Index
134
3HAC 021111-001

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Product manual (part 1 of 2), procedures

Product manual (part 1 of 2)

Copyright 2004 ABB All right reserved.

1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

1.3.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.0.1 Transporting and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

2.1.1 Lifting the Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

3.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

3.1.1 Oil in gears 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

3.1.3 Lubricating spring brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.2.1 Changing the motor of axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.3.1 Changing the motor of axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.4.1 Changing the motor of axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.5.1 Changing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.6.1 Changing serial measuring boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.7.1 Dismantling the wrist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

5.1.1 How to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

5.2: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

5.2.1 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

5.3.1 Calibration, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

5.4.1 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

7.0.1 Alternative calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Who should read

This manual contains instructions for

mechanical and electrical installation of the manipulator

maintenance of the manipulator

mechanical and electrical repair of the manipulator.

This manual should be used during

repair work and calibration.

This manual is intended for:

The reader should...

be a trained maintenance/repair craftsman

have the required knowledge of mechanical and electrical installation/repair/maintenance work.

The manual is organized in the following chapters:

Installation and commissioning

Information about installation of the manipulator.

Information about maintenance work, including maintenance schedules.

Information about repair work.

Information about calibration of the manipulator.

Environmental information about the manipulator.

0.0.2 Product documentation, M2000

0.0.2 Product documentation, M2000

Maintenance (descriptions of all required preventive maintenance procedures including periodicity)

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

Additional procedures, if any (calibration, decommissioning).

Product manual, reference information

Foldouts or exploded views

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

0.0.2 Product documentation, M2000

0.0.3 Product documentation, M2004

0.0.3 Product documentation, M2004

Maintenance (descriptions of all required preventive maintenance procedures including periodicity)

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

Additional procedures, if any (calibration, decommissioning).

Product manual, reference information

Foldouts or exploded views

RAPID Overview : An overview of the RAPID programming language.

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