IRC5-IRB4400 Prod Man Part1 3HAC022032-001 - Procedures - Rev - en PDF

Product manual, procedures
Articulated robot
IRB 4400 - 45
IRB 4400 - 60
IRB 4400 - L10
IRB 4400 - L30
IRB 4400 - LS
M2000, M2004

3HAC 022032-001
Revision -
Articulated robot
IRB 4400 - 45
IRB 4400 - 60
IRB 4400 - L10
IRB 4400 - L30
IRB 4400 - LS
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, fit-
ness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from use of
this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB’s written per-
mission, and contents thereof must not be imparted to a third party nor be used for any unau-
thorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
©Copyright 2004 ABB All right reserved.

ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
0.0.2 Reading the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
0.0.3 Product documentation, M2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
0.0.4 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1: Safety, service 15
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.2: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
1.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
1.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
1.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
1.2.6 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
1.3: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
1.3.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
1.3.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
1.3.3 Emergency release of the manipulator’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
1.3.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
1.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
1.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
1.3.7 Work inside the manipulator’s working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
1.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
2: Installation and commissioning 33

2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
2.1: Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.1.1 Pre-installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.1.2 Working range, IRB 4400/45 and /60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.1.3 Working range, IRB 4400/L30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
2.1.4 Working range, IRB 4400/L10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
2.1.5 Working range, IRB 4400/S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
2.2: On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
2.2.1 Lifting manipulator with round slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
2.2.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
2.2.3 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
2.2.4 Fitting equipment on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
2.2.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
2.3: Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
2.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
2.3.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2.3.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
2.3.4 Electrically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
2.3.5 Unlimited working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
2.4: Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
2.4.1 Customer connection on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
2.4.2 Customer connections on upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
3HAC 022032-001 3
Table of Contents
3: Maintenance 71
3.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.1: Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.1.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.1.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.2: General maintenance activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.2.1 Inspection of mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.2.2 Replacement of battery pack, measuring system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.2.3 Cleaning of manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.3: Change and checking of oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.3.1 Oil in gearbox unit, axis 1-2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.3.2 Inspection of oil levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.3.3 Oil change, gearbox axis 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.3.4 Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10) . . . . . . . . . . . . . 86
3.3.5 Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4: Repair 93
4.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.1: General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.1.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.1.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.1.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2: Complete robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2.1 Removal of cable harness, axes 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2.2 Refitting of cable harness, axes 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2.3 Removal of cable harness, axes 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2.4 Refitting of cable harness, axes 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.2.5 Removal of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.2.6 Refitting of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.3: Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.3.1 Removal of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.3.2 Refitting of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.3.3 Removal of wrist unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.3.4 Refitting of wrist unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.3.5 Replacement of arm house unit, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.3.6 Replacement of mechanical stop, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.3.7 Replacement of signal cabling, upper arm (option 042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.3.8 Measuring the play, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.3.9 Measuring the play, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.4: Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.4.1 Removal of lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.4.2 Refitting of lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.4.3 Removal of tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.4.4 Refitting of tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.4.5 Removal of parallel arm /Removal of bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.4.6 Refitting of parallel arm /Refitting of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.5: Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.5.1 Removal of balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.5.2 Refitting of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.5.3 Replacement of serial measurement unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.5.4 Replacement of pushbutton unit for brake release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.5.5 Replacement of mechanical stop pin, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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4.6: Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180

4.6.1 Removal of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
4.6.2 Refitting of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
4.6.7 Adjustment of motors, axes 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
4.6.8 Removal of motor, axes 4, 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
4.6.10 Refitting of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
4.6.11 Refitting of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
4.7: Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
4.7.1 Removal of gearbox unit, axes 1-2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
4.7.2 Refitting of gearbox unit, axes 1-2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
4.7.3 Adjusting play on axis 4, intermediate gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
5: Calibration 219
5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
5.1: Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
5.1.1 How to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
5.1.2 Calibration, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
5.2: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
5.2.1 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
5.2.2 Directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
5.2.3 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
5.2.4 Positions and directions of sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
5.2.5 Initialization of Levelmeter 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
5.3: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
5.3.1 Fine calibration procedure on TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
5.3.2 Resetting of Levelmeter 2000 and sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
5.3.3 Calibration, axis 1, IRB 4400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
5.3.4 Calibration, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
5.3.9 Updating the revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
5.4: After calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
5.4.1 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
6: Calibration, M2004 251

6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
3HAC 022032-001 5
Table of Contents
6 3HAC 022032-001
0.0.1 Overview
0.0.1 Overview
About this This manual contains instructions for

manual • mechanical and electrical installation of the manipulator
• maintenance of the manipulator
• mechanical and electrical repair of the manipulator.
Usage This manual should be used during

• installation, from lifting the manipulator to its work site and securing it to the foundation
to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read This manual is intended for:

this manual? • installation personnel
• maintenance personnel
• repair personnel.
Prerequisites The reader should...

• be a trained maintenance/repair craftsman
• have the required knowledge of mechanical and electrical installation/repair/mainte-
nance work.
Organization of The manual is organized in the following chapters:

chapters
Chapter Contents
Safety, service Safety information
Installation and commissioning Information about installation of the manipulator.
Maintenance Information about maintenance work, including mainte-
nance schedules.
Repair Information about repair work.
Calibration Information about calibration of the manipulator.
References
Reference Document Id
3HAC 022032-001 Revision - 7

0.0.1 Overview
Revisions
Revision Description
- First edition.
Replaces previous manuals:
• Installation and Commssioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Model M2004 implemented.
8 Revision - 3HAC 022032-001

0.0.2 Reading the product manual
General Information in the Product manual is written with specific principles. This section describes
some of the principles.
Reading the The instructions contain references to figures, tools, material etc. The references are read as
instructions described below.
References to fig- The instructions often include references to components or attachment points located on the
ures manipulator. The components or attachment points are marked with italic text in the instruc-
tions and completed with a reference to the figure where the current component or attachment
point is shown.
The denomination in the instruction for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in an instruction.
Step Action Note/Illustration

8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox .
References to The instructions often include references to equipment (spare parts, tools etc.) required for
required equip- the different actions in the instruction. The equipment is marked with italic text in the instruc-
ment tions and completed with a reference to the section where the equipment is listed with further
information, i.e. article number, dimension.
The denomination in the instruction for the component or attachment point corresponds to the
denomination in the referenced list.
The table below shows an example of a reference to a list of required equipment, from a step
in an instruction.

3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment .
3HAC 022032-001 Revision - 9

Danger levels The table below defines the captions specifying the danger levels used thoughout this manual.
Symbol Designation Signification

DANGER Warns that an accident will occur if the instruc-
tions are not followed, resulting in a serious or
fatal injury and/or severe damage to the product.
danger It applies to warnings that apply to danger with,
for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous
gases, risk of crushing, impact, fall from height
etc.
WARNING Warns that an accident may occur if the instruc-
tions are not followed, that can lead to serious
injury, possibly fatal, and/or great damage to the
warning product. It applies to warnings that apply to dan-
ger with, for example, contact with high voltage
electrical units, explosion or fire risk, risk of poi-
sonous gases, risk of crushing, impact, fall from
height etc.
CAUTION Warns that an accident may occur if the instruc-
tions are not followed, that can result in injury and
or damage to the product. It also applies to warn-
caution ings of risks that include burns, eye injury, skin
injury, hearing damage, crushing or slipping, trip-
ping, impact, fall from height etc. Furthermore, it
applies to warnings that include function require-
ments when fitting and removing equipment,
where there is a risk of damaging the product or
causing a breakdown.
NOTE Note symbols alert you to important facts and
conditions.
Note
TIP Tip symbols advice you to specific instructions,

where to find additional information or how to per-
form a certain operation in an easier way.
Tip
ELECTRICAL SHOCK The electrocution or electrical shock symbol indi-

cates electrical hazards which could result in
severe personnel injury or death.
Electrical shock
10 Revision - 3HAC 022032-001

0.0.3 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 All hardware, manipulators and controller cabinets, will be delivered with a Product manual
manuals that is divided into two parts:
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical con-
nections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures includ-
ing periodicity)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning).
Product manual, reference information
• Reference information (article numbers for documentation refered to in Product man-
ual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams.
Software manuals The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during oper-
ation.
A complete listing of all available software manuals is available from ABB.
Hardware option Each hardware option is supplied with its own documentation. Each document set contains
manual the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.
3HAC 022032-001 Revision - 11

12 Revision - 3HAC 022032-001

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 All hardware, manipulators and controller cabinets, will be delivered with a Product manual
manuals that is divided into two parts:
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical con-
nections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures includ-
ing periodicity)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning).
Product manual, reference information
• Reference information (article numbers for documentation refered to in Product man-
ual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams.
RobotWare The following manuals describe the robot software in general and contain reference informa-
manuals tion 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 parame-
ters and configuration workflows.
Application Specific applications (e.g. software or hardware options) are described in Application man-
manuals uals . An application manual can describe one or several applications.
An application manual generally contains information about:
• 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
3HAC 022032-001 Revision - 13

Operating This group of manuals is aimed at those having first hand operational contact with the robot,
Manuals i.e. cell 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
Miscellaneous A number of manuals provide generic descriptions of the robot and robot system. These
include:
• Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)
14 Revision - 3HAC 022032-001

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 instal-
lation, 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 dan-
gers 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 manipulator´s arm
• Brake testing
• Risk of disabling function "Reduced speed 250 mm/s"
• Safe use of the Teach Pendant Unit enabling device
• Work inside the manipulator´s working range
• Signal lamp (optional)
3HAC 022032-001 Revision - 15

1 Safety, service
1.1.1 Safety, service - General
1.1: General information
1.1.1 Safety, service - General
Validity and The information does not cover how to design, install and operate a complete system, nor
responsibility 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 indus-
trial robot, described in the applicable documents, e.g. User’s Guide and Product Manual.
Connection of Apart from the built-in safety functions, the robot is also supplied with an interface for the
external safety connection of external safety devices. Via this interface, an external safety function can inter-
devices act 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 con-
necting safety devices between the robot and the peripheral equipment.
16 Revision - 3HAC 022032-001

1 Safety, service
1.1.2 Limitation of Liability
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.
3HAC 022032-001 Revision - 17

1 Safety, service
1.1.3 Related information
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 User’s Guide Start-up
Restricting the working space Product manual for the manipulator Installation and
commissioning
18 Revision - 3HAC 022032-001

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.
3HAC 022032-001 Revision - 19

1 Safety, service
1.2.2 Safety risks related to tools/workpieces
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.
20 Revision - 3HAC 022032-001

1 Safety, service
1.2.3 Safety risks related to pneumatic/hydraulic systems
1.2.3 Safety risks related to pneumatic/hydraulic systems
General Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy • Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Safe design • Gravity may cause any parts or objects held by these systems to drop.
• Dump valves should be used in case of emergency.
• Shot bolts should be used to prevent tools, etc., from falling due to gravity.
3HAC 022032-001 Revision - 21

1 Safety, service
1.2.4 Safety risks during operational disturbances
1.2.4 Safety risks during operational disturbances
General • The industrial robot is a flexible tool which can be used in many different industrial
applications.
• All work must be carried out professionally and in accordance with the applicable
safety regulations.
• Care must be taken at all times.
Qualified per- • Remedial action must only be carried out by qualified personnel who are familiar with
sonnel the entire installation as well as the special risks associated with its different parts.
Extraordinary If the working process is interrupted, extra care must be taken due to risks other than those
risks associated with regular operation. Such an interruption may have to be rectified manually.
22 Revision - 3HAC 022032-001

1 Safety, service
1.2.5 Safety risks during installation and service
1.2.5 Safety risks during installation and service
General risks • The instructions in the Product Manual - Installation and Commissioning must always
during instal- be followed.
lation and service • Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are available
for the installation in question.
• Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
Nation/region To prevent injuries and damage during the installation of the robot system, the regulations
specific regula- applicable in the country concerned and the instructions of ABB Robotics must be complied
tions with.
Non-voltage • Safety zones, which have to be crossed before admittance, must be set up in front of
related risks 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 tempera-
ture of the motors or oil spills that can occur on the robot.
To be observed • The supplier of the complete system must ensure that all circuits used in the safety
by the supplier of function are interlocked in accordance with the applicable standards for that function.
the complete • The supplier of the complete system must ensure that all circuits used in the emer-
system gency stop function are interlocked in a safe manner, in accordance with the applica-
ble standards for the emergency stop function.
3HAC 022032-001 Revision - 23

1 Safety, service
1.2.6 Risks associated with live electric parts
1.2.6 Risks associated with live electric parts
Voltage related • Although troubleshooting may, on occasion, have to be carried out while the power
risks, general supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
• The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot’s working space.
Voltage related A danger of high voltage is associated with the following parts:
risks, controller • 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 exter-
nal 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 pro-
cess
• The external voltage connected to the control cabinet remains live even when the
robot is disconnected from the mains.
• Additional connections
Voltage related A danger of high voltage is associated with the manipulator in:
risks, manipu- • The power supply for the motors (up to 800 VDC)
lator
• The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
Voltage related Tools, material handling devices, etc., may be live even if the robot system is in the OFF
risks, tools, position. Power supply cables which are in motion during the working process may be dam-
material handling aged.
devices, etc
24 Revision - 3HAC 022032-001

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.
3HAC 022032-001 Revision - 25

1 Safety, service
1.3.2 Fire extinguishing
1.3.2 Fire extinguishing

Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipula-
tor or controller)!
26 Revision - 3HAC 022032-001

1 Safety, service
1.3.3 Emergency release of the manipulator’s arm
1.3.3 Emergency release of the manipulator’s arm
Description In an emergency situation, any of the manipulator’s axes may be released manually by push-
ing 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 Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
3HAC 022032-001 Revision - 27

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 per-
formed 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 manip-
ulator 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.
28 Revision - 3HAC 022032-001

1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
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.
3HAC 022032-001 Revision - 29

1 Safety, service
1.3.6 Safe use of the Teach Pendant Unit
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
robot’s working space. This is to prevent anyone else taking control over the robot without
the programmer knowing.
30 Revision - 3HAC 022032-001

1 Safety, service
1.3.7 Work inside the manipulator’s working range
1.3.7 Work inside the manipulator’s working range

Warning!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
- The operating mode selector on the controller must be in the manual mode position to render
the enabling device operative and to block operation from a computer link or remote control
panel.
- The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in posi-
tion < 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 28.
3HAC 022032-001 Revision - 31

1 Safety, service
1.3.8 Signal lamp (optional)
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 infor- Further information about the MOTORS ON/MOTORS OFF mode may be found in the chap-
mation ter Description, Control System in the Product manual for the controller.
32 Revision - 3HAC 022032-001

2 Installation and commissioning
2.0.1 Introduction
2: Installation and commissioning

2.0.1 Introduction
General This chapter contains information for installing the manipulator to the working site.
More detailed technical data, such as load diagram, permitted extra loads (equipment) and
location of extra loads (equipment), may be found in the Product Specification for the manip-
ulator.
3HAC 022032-001 Revision - 33

2.1.1 Pre-installation procedure
2.1: Unpacking
General These instructions are to be used when unpacking and installing the manipulator for the first
time. They also contain information useful later during re-installation of the manipulator.
Checking the pre- The check-list below details what must be observed before proceeding with the actual instal-
requisites for lation of the manipulator:
installation
1. Make sure only qualified installation personnel conforming to all national and local
codes are allowed to perform the installation.
2. Make sure the manipulator is not damaged, by visually inspecting the manipulator
and control cabinet exterior.
3. Make sure the lifting device to be used is dimensioned to handle the weight of the
manipulator as specified in Weight, manipulator on page 34.
4. If the manipulator is not to be installed directly, it must be stored as described in
Storage conditions, manipulator on page 36.
5. Make sure the expected operating environment of the manipulator conforms to
the specifications as described in Operating conditions, manipulator on page 37.
6. Before taking the manipulator to the installation site, make sure the site conforms
to Loads on foundation, manipulator on page 35and Protection classes on page
37.
7. When the manipulator is not fastened to the floor and standing still, the manipu-
lator is not stable in the work area. Care must be taken when the arms are moved,
so that the center of gravity is not displaced which may cause the manipulator to
tip over.
8. When these prerequisites are met, the manipulator may be taken to its installation
site as described in section On-site installation on page 42.
Weight, manipu- The table below shows the weights of the different models:
lator
Manipulator model Weight

IRB 4400/45 985 kg
IRB 4400/60 1040 kg
IRB 4400/L10 1040 kg
IRB 4400/L30 1060 kg
IRB 4400/S 1290 kg
L - Long arm
S - Shelf mounted manipulator
34 Revision - 3HAC 022032-001

Loads on foun- The table below shows the various forces and torques working on the manipulator during
dation, manipu- different kinds of operation. Stress forces for the manipulator version IRB 4400/S are detailed
lator separately in the following table.
Note! These forces and torques are extreme values that are rarely encountered during oper-
ation. The values also never simultaneously reach their maximum!
The rigidity of the foundation must be designed to minimize the affects of dynamic behaviour
on the robot. For optimal performance, the frequency for the foundation bearing the robot
must be higher than 30 Hz.
TuneServo can be used to adapt robot tuning for a non-optimal foundation.
Fxy and Mxy are vectors that can have any direction on the xy plane.
The illustration below shows the directions of the stress forces.
Z
xx0300000254
Force Endurance load (in operation) Max. load (emergency stop)

Force xy ±7500 N ±9000 N
Force z +9500 ±2000 N +9500 ±3000 N
Torque xy ±14000 Nm ±16000 Nm
Torque z ±2000 Nm ±4000 Nm
3HAC 022032-001 Revision - 35

Loads on founda-
tion, manipulator Z
IRB 4400/S
0-30º
X
30º
X’
Z’ Z X
xx0300000255
Force Endurance load (in operation) Max. load (emergency stop)

Force x ±5000 N ±7000 N
Force y ±6000 ±9000 N
Force z 10 000 ±5000 N 10 000 ±7000 N
Torque x ±8500 Nm ±11 500 Nm
Torque y 3500 ±14 000 Nm 3500 ±11 500 Nm
Torque z ±6500 Nm ±11 000 Nm
Force x' 5000 ±5000 N 5000 ±7000 N
Force y' ±6000 N ±9000 N
Force z' 8500 ±3000N 8500 ±5500 N
Torque x' ±9500 Nm ±12 000 Nm
Torque y' 3500 ±7500 Nm 3500 ±11 500 Nm
Torque z' ±2000 Nm ±5500 Nm
Storage condi- The table below shows the allowed storage conditions for the manipulator:
tions, manipu-
lator
Parameter Value
Min. ambient temperature -25°C
Max. ambient temperature +55°C
Max. ambient temperature (less than 24 hrs) +70°C
Max. ambient humidity 95% at constant temperature
36 Revision - 3HAC 022032-001

Operating condi- The table below shows the allowed operating conditions for the manipulator:
tions, manipu-
lator
Parameter Value
Min. ambient temperature +5°C
Max. ambient temperature +45°C
Max. ambient humidity 95% at constant temperature
Protection The table below shows the protection class of the manipulator:
classes
Manipulator Protection class

Standard version IP54
Foundry version IP67, steam washable
3HAC 022032-001 Revision - 37

2.1.2 Working range, IRB 4400/45 and /60
2.1.2 Working range, IRB 4400/45 and /60
Extreme posi- The illustration below shows the extreme positions of the robot arms IRB 4400/45 and /60:
tions 53
R1
140 880 300

A-A
Pos 1
A Pos 0
Pos 5
(6
0 kg
R
Pos 6 (45 51
kg 0)
R4
78
)
Pos 2
Pos 3 5
56
R
640
Pos 4
370 200
390 530
(1223) 731
1955
xx0300000241
Position X Position Z Angle Axis 2 Angle Axis 3

Pos no.
(mm) (mm) (degrees) (degrees)
0 1080 1720 0 0
1 887 2140 0 -30
2 708 836 0 65
3 1894 221 95 -60
4 570 -126 95 40
5 51 1554 -70 40
6 227 1210 -70 65
Robot motion The table below specifies the types and ranges of the robot motion in every axis.
Location of motion Type of motion Range of movement

Axis 1 Rotation motion +165°to -165°
Axis 2 Arm motion +95°to -70°
Axis 4 Wrist motion +200°to -200°
Axis 5 Bend motion +120°to -120°
Axis 6 Turn motion +400°to -400°
38 Revision - 3HAC 022032-001

2.1.3 Working range, IRB 4400/L30
Extreme posi- The illustration below shows the extreme positions of the robot arm IRB 4400/L30:
tions C 53
R1
140 1380 300 A-A
A G
B
(6
0k
g
R
51
0)
D
4
18
5
56
R
F 640
370 200
390 530
(1453) 978
2432
xx0300000242
Positions in Position X Position Z Angle Axis 2 Angle Axis 3

illustration (mm) (mm) (degrees) (degrees)
B 1580 1720 0 0
C 1320 2390 0 -30
D 919 383 0 65
E 2303 -66 95 -60
F 180 -448 95 42
G 484 1804 -70 40
H 725 1254 -70 65

3HAC 022032-001 Revision - 39

Extreme posi- The illustration below shows the extreme positions of the robot arm IRB 4400/L10:
tions
C
85 1500 300
A G 8.5
B R9
A
A-A
0)
51
R
g
0k
(6
E
5
56
R
390 530
640
F
300 200
(1477) 1070
2547
xx0300000244
Position in
Position X Position Z Angle Axis 2 Angle Axis 3
illustratio
(mm) (mm) (degrees) (degrees)
n
B 1700 1720 0 0
C 1424 2450 0 -30
D 970 274 0 65
E 2401 -135 95 -60
F 500 -786 95 23.6
G 588 1864 -70 40
H 845 1265 -70 65

40 Revision - 3HAC 022032-001

2.1.5 Working range, IRB 4400/S
2.1.5 Working range, IRB 4400/S
Extreme posi- The illustration below shows the extreme positions of the robot arm IRB 4400/S:
tions
0
30
15
0
C
G
(10
80
13
40
89
17
0
20
0
14
B
H
A
23
2
68
A
30
º
23
D
90
65
R5
181
(1453) (1291) 0
53
F
2 00
0
37 0
39
60
kg
R5
8
97
10
E
32
24
70
8
5 3)
(1 4
xx0300000243
Positions in Position X Position Z Angle Axis 2 Angle Axis 3

illustration (mm) (mm) (degrees) (degrees)
B 1580 1720 0 0
C 1320 2390 0 -30
D 919 383 0 65
E 2360 120 90 -60
F 239 -417 90 44
G 484 1804 -70 40
H 725 1254 -70 65

3HAC 022032-001 Revision - 41

2.2.1 Lifting manipulator with round slings
2.2: On-site installation
General Lift the manipulator using lifting straps and a traverse crane according to this section.
The instructions are separated for the manipulator version IRB 4400/45, /60, /L10, /L30 and
for IRB 4400/S.
Required
equipment
Equipment Art. no. Note
Crane Lifting capacity: 2100kg (max. load at 90°)
Round slings, 2 m Lifting capacity/sling: 1100kg
2 pcs for version IRB 4400/45, /60, /L10 and /L30
3 pcs for version IRB 4400/S if the erection position is
to be 30°
Lifting lugs Type: OBK 7-8
Warning!
The manipulator weighs 1300 kg! All lifting equipment used must be dimensioned accord-
ingly!
Warning!
Personnel must not, under any circumstances, be present under the suspended load!
Caution!
Failure to attach the straps correctly can cause the suspended load to tilt suddenly and cause
both personal injury and severe damage to the load.
42 Revision - 3HAC 022032-001

Lifting, manipu- The lifting equipment is attached to the manipulator as shown in the figure below.
lator version IRB
4400/45, /60, /L10,
/L30
xx0300000245
A Angle (degrees specified for the different versions in the lifting instruction)
B Lifting lug
Lifting The procedure below details how to lift the complete manipulator (IRB 4400/45, /60, /L10, /
instruction, IRB L30).
4400/45, /60, /L10,
/L30
Step Action Info/Illustration
1. Release the brakes manually, to make it Detailed in section Manually releasing
possible to alter the positions of the the brakes on page 46.
arms.
2. Move the manipulator to the calibration
position.
3HAC 022032-001 Revision - 43


3. Move the lower arm backwards to get Angle (A) is shown in the figure Lifting,
balance, according to angle specified to manipulator version IRB 4400/45, /60, /
the right. L10, /L30 on page 43.
• IRB 4400/45 and /L30: A: -5°
• IRB 4400/60 and /L10: A: 0°
4. Attach the round slings to the special eye Shown in the figure Lifting, manipulator
bolts on the gearbox unit for axes 2 and version IRB 4400/45, /60, /L10, /L30 on
3 using lifting lugs . page 43.
The roundsling and lifting lug dimensions
must comply with the applicable stan-
dards specified in Required equipment
on page 42.
5. Lift the manipulator to its installation site.
Make sure the slings do not rub against
any sharp edges!
Lifting manipu- The lifting equipment is attached to the manipulator as shown in the figure below.
lator version IRB
4400/S
(1) A (2)
x
B 30º
x-x
xx0300000247
(1) Lifting angle for the manipulator: 0°

(2) Lifting angle for the manipulator: 30°
A Angle (degrees specified for the different versions in the lifting instruction)
B Axis 2
C Lifting lug
44 Revision - 3HAC 022032-001

Lifting The procedure below details how to lift the complete manipulator (IRB 4400/S).
instruction, IRB
4400/S
1. Release the brakes manually, to make it Detailed in section Manually releasing
possible to alter the positions of the the brakes on page 46.
arms.
position.
3. Move the lower arm forward to get bal- Angle (A) is shown in the figure Lifting
ance, according to angle specified to the manipulator version IRB 4400/S on page
right. 44.
If the manipulator liftangle is:
• 0°, then A=25°
• 30°, then A=0°
4. Attach the round slings to the special eye Attachment points are shown in the fig-
bolts on the gearbox unit for axes 2 and ure Lifting manipulator version IRB 4400/
3 using lifting lugs. S on page 44.
If the lifting angle of the manipulator is The roundsling and lifting lug dimensions
more than 0°, a round sling must also be must comply with the applicable stan-
attached to the rear of the robot. dards specified in Required equipment
on page 42.
5. Lift the manipulator to its installation site.
Make sure the slings do not rub against
any sharp edges!
3HAC 022032-001 Revision - 45

2.2.2 Manually releasing the brakes
General The section below details how to release the holding brakes of each axis’ motor.
This may be done in one of three ways:
• using the pushbutton when the manipulator is connected to the controller.
• using the pushbutton on the manipulator with an external power supply.
• using an external voltage supply directly on the respective brake.
Danger!
When releasing the holding brakes, the manipulator axes may move very quickly and some-
times in unexpected ways! Make sure no personnel is near the manipulator arm!
Using the push- The procedure below details how to release the holding brakes with pushbuttons, when the
button when the manipulator is connected to the controller.
manipulator is
connected to the
controller Step Action Info/Illustration
1. The internal brake release unit is located at
the base of the manipulator.
R1.CP/CS R1.MP
R1.SMB
xx0300000198
The brake release unit is equipped

with six buttons for controlling the
axes brakes. The buttons are num-
bered according to the numbers of the
axes.
46 Revision - 3HAC 022032-001


2. Release the holding brake on a particular
axis by pressing the corresponding button
on the pushbutton unit and keeping it
depressed.
The brake will function again as soon as the
button is released.
Using the push- The procedure below details how to release the holding brakes with the pushbuttons, when
button on the the manipulator is not connected to the controller.
manipulator with
an external power
supply Step Action Note/Illustration
1. Connect an external 24VDC power supply
to the connector R1.MP on the manipula-
tor base, as shown in the figure to the
right.
Note! Be careful not to interchange the
24V and 0V pins.
If they are mixed up, damage can be
caused to the brake release unit and the
system board.
Danger!
Incorrect connections can cause all

R1.CP/CS
brakes to be released simultaneously! R1.MP
R1.SMB
0V B14
+24V B16
xx0300000200
Connect to connector R1.MP:

• 0V: pin B14 or B15
• +24V: pin B16
2. Release the holding brake on a particular The brake release unit is equipped with
axis by pressing the corresponding button six buttons for controlling the axes
on the pushbutton unit and keeping it brakes. The buttons are numbered
depressed. according to the numbers of the axes.
The brake will function again as soon as See the previous figure.
the button is released.
3HAC 022032-001 Revision - 47

Using an external The procedure below details how to release the holding brake of a specific axis by supplying
voltage supply external voltage directly on the brake.
directly on the
respective brake
1. Every axis has a holding brake built into Make the connection to current motor
the axis motor. This holding brake may according to the Circuit Diagram
be released by connecting 24VDC See chapter Circuit diagram in the Prod-
power supply directly to one of the con- uct manual, reference information.
nectors in the motor.
Danger!
When power is connected directly to

the brake cable, the brake will be
released immediately when the power
is switched.
This may cause som unexpected
manipulator movements!
48 Revision - 3HAC 022032-001

2.2.3 Orienting and securing the manipulator
General This section details how to orient and secure the manipulator to the base plate after fitting it
to the foundation.
Securing parts/ The table below specifies the type of securing screws and washers to be used to secure the
facts manipulator to the base plate/foundation.
Securing parts/fact Dimension/art. no. Amount/Note

Securing screws, oiled M20 3 pcs
Washers Thickness: 3 mm 3 pcs
Outer diameter: 36 mm
Inner diameter: 21 mm
Guide sleeves 2151 0024-169 2 pcs
Added to the rear bolt holes, to allow
the same robot to be re-mounted
without program adjustments.
Tightening torque 350 - 400 Nm Oiled screws
Level surface requirements
0.5
xx0300000251
Hole configu- The illustration below shows the hole configuration and hole dimensions of the manipulator
ration and dimen- base, seen from below.
sions
The cut x-x shows the dimension of the rear bolt holes, where the guide sleeves may be used.
Ø22
B Ø22
Ø35
xx0300000252
A Rear bolt holes

B Center line, axis 1
3HAC 022032-001 Revision - 49

Orienting and The procedure below details how to orient and secure the manipulator to the base plate after
securing the fitting the plate to the foundation.
manipulator
Warning!
The manipulator weighs 1300 kg! All lifting equipment used must be dimensioned accord-
ingly!

1. Lift the manipulator. Detailed in section Lifting manipula-
tor with round slings on page 42.
2. Move the manipulator to the vicinity of the
installation site.
3. Fit two guide sleeves to the rear bolt holes in Art. no. is specified in Securing
the base. parts/facts on page 49.
Shown in the figure Hole configura-
tion and dimensions on page 49.
4. Guide the manipulator gently using M20
screws while lowering it into its mounting
position.
5. Fit the securing screws and washers in the Specified in Securing parts/facts on
base attachment holes. page 49.
Attachment holes shown in the fig-
ure Hole configuration and dimen-
sions on page 49.
6. 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 section Loads on
foundation, manipulator on page 35.
50 Revision - 3HAC 022032-001

2.2.4 Fitting equipment on manipulator
General The manipulator features mounting holes for additional equipment.

Access to any of the following mounting holes may be obstructed by any additional cabling,
equipment etc. fitted by the robot user. Make sure the required mounting holes are accessible
when planning the robot cell.
Never drill a hole in the manipulator without first consulting ABB!
Fitting equipment The illustration below shows the mounting holes available for fitting extra equipment on the
on upper arm, IRB upper arm for robot versions IRB 4400/45, /60, /L30, /S.
4400/45, /60, /L30, The shaded area indicates the permitted positions (center of gravity) for any extra equipment
/S
mounted in the holes.
A
A
250 175
F G 150 300
B
D
390
20o 150
B -B 340
E 144 115
B
54
15
29.5
29.5
106 110
200
D-D A- A I
K
J
xx0300000264
E Max. 15 kg
F M8 (2x), holes used if option 043 is chosen. Depth of thread: 9 mm
G M8 (3x) Depth of thread: 14 mm
H 571 mm for IRB 4400/45 and /60. 1071 mm for IRB 4400/S and /L30
I Max. 5 kg for IRB 4400/45 and /60 at max. handling weight
J 5 kg for IRB 4400/S and /L30 if the handling weight is max. 25 kg. If the
handling weight is 30 kg: 0 kg allowed!
K M6 (2x), tapped depth 12 mm
3HAC 022032-001 Revision - 51

on upper arm, IRB upper arm for robot versions IRB 4400/L10.
4400/L10
The shaded area indicates the permitted positions (center of gravity) for any extra equipment
A A
250 175
D E 150 300
B
390
20 o 150
B-B
110 115 54
B
C
1221
G
300
Ø240
110
A-A
F
xx0300000265
C Max. 15 kg
D M6 (2x) Depth of thread: 9 mm
E M8 (3x) Depth of thread: 14 mm
F Max. 2 kg
G M5 (2x)
52 Revision - 3HAC 022032-001

on gearbox unit gearbox unit.
The shaded area indicates the permitted positions (center of gravity) for any extra equipment
195 C
Ø10
120 o (3x)
B
C- C C
xx0300000266
A M8 (3x), R=2. Depth 16 mm (if option 623 is chosen, these holes are occu-
pied)
B Max. 35 kg for IRB 4400/45, /60, /L10, /L30 (0 kg for IRB 4400/S)
Fitting equipment The illustration below shows the mechanical interface for the mounting flange, robot version
on mounting IRB 4400/45, /60, /L30 and /S.
flange, IRB 4400/
45, /60, /L30, /S A
+0.015
Ø8 -0 0.05 A
A M10 (6x)
8
R 50
9 60o
15
A
A-A
xx0300000267
3HAC 022032-001 Revision - 53

Fitting equipment The illustration below shows the mechanical interface for the mounting flange, robot version
on mounting IRB 4400/L10.
flange, IRB 4400/
10 A
+0.012
Ø 6 -0 H7 C
0.05 B
B
8
M6 (6x)
R =25
A
7
A- A
xx0300000268
C The hole can go through
54 Revision - 3HAC 022032-001

2.2.5 Loads
2.2.5 Loads
General Any loads mounted on the manipulator must be defined correctly and carefully (with regard
to the position of center of gravity and inertia factor) in order to avoid jolting movements and
overloading the motors. If this is not done correctly operational stops may result.
References Load diagrams, permitted extra loads (equipment) and their positions are specified in the
Product Specification. The loads must also be defined in the software as detailed in User’s
Guide.
Stop time and Manipulator motor brake performance depends on any loads attached. For further informa-
braking distances tion about brake performance, please contact ABB Robotics.
3HAC 022032-001 Revision - 55

2.3.1 Introduction
2.3: Restricting the working range
2.3.1 Introduction
General 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.
The working range of the manipulator may be limited to eliminate the risk of collisions. The
following axes may be restricted:
• Axis 1, hardware (mechanical stop) and software (signal from adjustable position
switch)
• Axis 2, hardware (mechanical stop)
• Axis 3, software (signal from limit switch)
This section describes the use of the mechanical stops and/or the position switches.
Limiting the working space using software is described in section System Parameters in the
User’s Guide . Art. no. for the manual is specified in section Document references .
56 Revision - 3HAC 022032-001

2.3.2 Mechanically restricting the working range of axis 1
Mechanically The working range of axis 1 can be restricted mechanically by fitting additional mechanical
restricting the stops to the base, as detailed in this section.
working range
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Mechanical stop, axis 1 3HAB 3833-1 Includes 2 additional stop
lugs, 8 attachment
screws, 8 plain washers
and a label
Attachment screw 9ADA 183-71 4 pcs/lug, included in
3HAB 3833-1
M12x60
Washer 9ADA 312-9 4 pcs/lug, included in
3HAB 3833-1
13x24x2,5
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
in the Product manual,
reference information.
Other tools and proce- These procedures include
dures may be required. references to the tools
See references to these required.
procedures in the step-by-
step instructions below.
3HAC 022032-001 Revision - 57

Additional stops The additional stops are fitted as shown in the figure below.
D
E
F
C
xx0300000258
B Mechanical stop lugs

C Attachment screw and washer
D Stop pin
E Max. working range with stop lugs (250°)
F Min. working range with stop lugs (127°)
Fitting, The procedure below details how to fit the additional mechanical stop to the base.
mechancial stop Mounting instructions are also supplied with the kit.
axis 1

1. Determine the position of the stop lugs and See the figure Additional stops on page
mark the hole positions on the base. 58 for guidance.
2. Drill Ø10.2 mm to a maximum depth of 45
mm and tap with M12 thread. Min. thread
depth 35 mm.
3. Fit the stop lugs firmly with attachment Specified in Required equipment on
screws and washers according to the fig- page 57.
ure Additional stops on page 58. M12x60, tightening torque: 82 Nm, oil
lubrication.
58 Revision - 3HAC 022032-001

Mechanically The working range of axis 2 can be restricted mechanically by fitting additional mechanical
restricting the stops (spacers and dampers) to the lower arm and gearbox unit axis 1-3, as detailed in this
working range section.
Required
equipment
Mechanical stop, axis 2 3HAC 4225-1 Includes spacers, damp-
ers, attachment screws
and nuts.
Spacer (damper) 3HAB 9185-1
Spacer 3HAC 3962-1
in the Product manual, ref-
erence information.
3HAC 022032-001 Revision - 59

Additional stops The additional mechanical stops (spacers and dampers) are fitted to the lower arm and the
gearbox unit, as shown in the figure below.
E
F
A B
G G
E
E
D
C
D
C
A B
G
H
C-C
D-D
xx0300000260
A View A of the lower arm

B View B of the lower arm
C Cut of the mech stop attachment
D Spacer
E Attachment screw, spacer (+nut)
F Damper
G Attachment screw, damper (+nut)
60 Revision - 3HAC 022032-001

Working ranges The working range of axis 2 can be restricted according to the table below. The table applies
to all robot versions except IRB 4400/FS.
Working range Damper, qty Spacer, qty

+95°/ -70° - -
+95°/ -40° - 2
+95°/ -10° 2 2
+65°/ -70° 2 -
+65°/ -40° 2 2
+65°/ -10° 4 2
+35°/ -70° 4 -
+35°/ -40° 4 2
+35°/ -10° 6 2
+5°/ -70°(not applicable on IRB 4400/S) 6 -
+5°/ -40°(not applicable on IRB 4400/S) 6 2
+5°/ -10°(not applicable on IRB 4400/S) 8 2
• Each damper is fitted with: 2 attachment screws and 2 hexagon nuts.

• Each spacer is fitted with: 1 attachment screw and 1 hexagon nut.
Fitting, The procedure below details how to fit the additional mechanical stop to the lower arm and
mechancial stop the gearbox unit.
axis 2
Mounting instructions are also supplied with the kit.

1. Determine the working range restriction. See Working ranges on page 61.
2. Fit both the spacers to either side of the Shown in the figure Additional stops on
gearbox unit, with the attachment screws page 60.
and nuts, spacer. Art. no. is specified in Required equip-
ment on page 59.
Attachment screw: 1 pc/spacer, M16x70.
Tightening torque: 156 Nm.
3. Fit the dampers to both sides of the lower Shown in the figure Additional stops on
arm with the attachment screws and page 60.
nuts, damper. Art. no. is specified in Required equip-
ment on page 59.
Attachment screws: 2 pcs/damper,
M10x60. Tightening torque: 49 Nm.
3HAC 022032-001 Revision - 61

2.3.4 Electrically restricting the working range of axis 3
Electrically The working range of axis 3 can be limited by fitting an electric switch on the gearbox for
restricting the axis 3, which senses the current position via a cam.
working range
Electrical stop All the separate parts of the electrical stop are fitted to axis 3 as shown in the figure below.
L
B C A
D
H
x G
E
M
F
x H K
x-x
I
J
R3.LS1
R3.LS2
xx0300000262
A Sealing with dust lip (3HAB 3701-14)

B Stud (2122 2012-867)
C All screws are locked with locking liquid
D Tap (3HAB 3798-1)
E Hexagon nut (9ADA 267-7)
F Disc (3HAB 3799-1)
G Screw (9ADA 618-44)
H Cam (3HAB 3800-1)
I Bracket (3HAB 8400-1)
J Limit switch complete (3HAB 8400-1)
K Screw (9ADA 629-50)
L Attachment screw (9ADA 183-35)
M Retaining ring (9ABA 135-18), reducing coupling (2686 015-3), washer
(2152 398-3)
62 Revision - 3HAC 022032-001

Required
equipment
Electrical stop, axis 3 3HAB 3795-1 Includes all spare parts
shown in the figure Electrical
stop on page 62.
Locking liquid 1269 0014-410 Loctite 242
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in
the Product manual, refer-
ence information.
procedures in the step-
by-step instructions
below.
Circuit Diagrams See chapter Circuit Dia-
grams in the Product man-
ual, reference information.
Fitting, electrical The procedure below details how to fit the electrical stop to axis 3.
stop axis 3 Mounting instructions are also supplied with the kit.

1. Remove the covers (A) from axis 3.
xx0300000263
2. All screws are locked with locking liquid , when Specified in Required equipment
fitted. on page 63.
3. Fit the electrical stop according to the figure Elec-
trical stop on page 62.
3HAC 022032-001 Revision - 63

2.3.5 Unlimited working range
Resetting the The function "Resetting the work area for an axis", included in Advanced Motions 3.0, can
work area for an also be used for axis 4. To enable this function, the mechanical stop on axis 4 should be
axis removed. Follow the procedure below to dismantle the mechanical stop. Also, see the Foldout
section in the Repair Manual .
Location of The mechanical stop of axis 4 is located as shown in the figure below.
mechanical stop, A more detailed view is shown in the Foldout section in the Repair Manual!
axis 4
A
x
C
x
B
A
x-x
xx0300000176
A Mechanical stop axis 4

B Damper axis 4
C Attachment screws, mech stop
Removal of The procedure below details how to remove the mechanical stop of axis 4, to enable the
mechanical stop, function "Resetting the work area for an axis".
axis 4
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
64 Revision - 3HAC 022032-001

Warning!
When the damper is removed from axis 4, the axis does not have a mechanical stop! If the
robot is provided with cabling on the upper arm, the cabling can be damaged when the func-
tion “Resetting the work area for an axis”is used, or if the robot is jogged uncalibrated.

1. Loosen the attachment screws, mech stop Shown in the figure Location of
and remove the mechanical stop, axis 4 . mechanical stop, axis 4 on page 64.
2. Slowly rotate axis 4 until the damper is visi-
ble through the hole.
3. Remove the damper.
4. Refit the mechanical stop to the axis 4 with 4 pcs, M8x16. Tightening torque: 24
its attachment screws. Nm.
3HAC 022032-001 Revision - 65

2.4.1 Customer connection on manipulator
2.4: Electrical connections
General For connection of extra equipment to the manipulator, cables and air hose are integrated into
the manipulator’s cabling, and there is one FCI UT071823SH44N and one FCI
UT071412SH44N connector on the rear part of the upper arm.
The customer connections are located on the manipulator as shown in the figure below.
C
xx0300000270
A R1.CP, R1.CS, Air R1/4"

B R2.CP, R2.CS, Air R1/4"
C R3.CP, R3.CS, Air R1/4"
Extra equipment Connections to the:

connections • air hose (R1/4”) is located on the rear part of the upper arm and at the base. Max. 8
bar. Inner hose diameter: 8 mm.
• signal cabling (option 042) are located on the front of the upper arm.
Number of signals: 23 (50V, 250mA), 10 (250V, 2A), one protective ground.
Connection sets To connect power and signal conductors to the manipulator base/upper arm connectors, the
following parts are recommended.
Connection set Connector Art. no. Content

Connection set R1.CP/CS R1.CP/CS 3HAC 12275-1 • socket for area of
(IRB 4400 Protection Stan- 0.14 - 0.5 mm 2
dard) • compression gland
for cables, diame-
ter 2 x 12 mm
• key pin
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Connection set Connector Art. no. Content

Connection set R1.CP/CS R1.CP/CS 3HAC 12276-1 • socket for area of
F (IRB 4400 Protection 0.14 - 0.5 mm 2
Foundry) • compression gland
for cables, diame-
ters 10 mm and 12
mm
• key pin
Connection set R2.CS/ R2.CS/R3.CS 3HAC 12327-1 • pins for cable area
R3.CS of 0.13 - 0.25 mm 2
• reduction hose,
bottled-shaped
• reduction hose,
angled
Connection set R2.CP/ R2.CP/R3.CP 3HAC 12326-1 • pins for cable area
R3.CP of 0.13 - 0.25 mm 2
• reduction hose,
bottled-shaped
• reduction hose,
angled
3HAC 022032-001 Revision - 67

2.4.2 Customer connections on upper arm
Customer con- The figure below shows the customer connections on the upper arm, including the optional
nection on upper signal lamp that can be fitted to the rear of the arm.
arm
A
C
xx0300000269
A R2.CP
B R2.CS
C Signal lamp (option)
D R3.H1 +, R3.H2 -
Power supply
connections on
upper arm Customer Contact on
Customer
Customer Contact Manipulator base
Signal name Terminal
on Upper arm, R2 (cable between manipulator
Controller
and controller not supplied)
CPA XT6.1 R2.CP.A RI.CP/CS.A1
CPB XT6.2 R2.CP.B RI.CP/CS.B1
CPC XT6.3 R2.CP.C RI.CP/CS.C1
CPD XT6.4 R2.CP.D RI.CP/CS.D1
CPE XT6.5 R2.CP.E RI.CP/CS.A2
CPF XT6.6 R2.CP.F RI.CP/CS.B2
R2.CP.G (Earth) RI.CP/CSP Earth
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Customer Contact on
Customer
Customer Contact Manipulator base
Signal name Terminal
on Upper arm, R2 (cable between manipulator
Controller
XT6.H R2.CP.H (Key pin)
CPJ XT6.7 R2.CP.J RI.CP/CS.C2
CPK XT6.8 R2.CP.K RI.CP/CS.D2
CPL XT6.9 R2.CP.L RI.CP/CS.A3
CPM XT6.10 R2.CP.M RI.CP/CS.B3
Signal connec-
tions on upper
arm Customer Contact on
Customer Customer
Manipulator base
Signal name Terminal Contact on Upper
(cable between manipulator
Controller arm, R2
CSA XT5.1 R2.CS.A R1.CS/CP.B5
CSB XT5.2 R2.CS.B R1.CS/CP.C5
CSC XT5.3 R2.CS.C R1.CS/CP.D5
CSD XT5.4 R2.CS.D R1.CS/CP.A6
CSE XT5.5 R2.CS.E R1.CS/CP.B6
CSF XT5.6 R2.CS.F R1.CS/CP.C6
CSG XT5.7 R2.CS.G R1.CS/CP.D6
CSH XT5.8 R2.CS.H R1.CS/CP.A7
CSJ XT5.9 R2.CS.J R1.CS/CP.B7
CSK XT5.10 R2.CS.K R1.CS/CP.C7
CSL XT5.11 R2.CS.L R1.CS/CP.D7
CSM XT5.12 R2.CS.M R1.CS/CP.A8
CSN XT5.13 R2.CS.N R1.CS/CP.B8
CSP XT5.14 R2.CS.P R1.CS/CP.C8
CSR XT5.15 R2.CS.R R1.CS/CP.D8
CSS XT5.16 R2.CS.S R1.CS/CP.A9
CST XT5.17 R2.CS.T R1.CS/CP.B9
CSU XT5.18 R2.CS.U R1.CS/CP.C9
CSV XT5.19 R2.CS.V R1.CS/CP.D9
CSW XT5.20 R2.CS.W R1.CS/CP.A10
CSX XT5.21 R2.CS.X R1.CS/CP.B10
3HAC 022032-001 Revision - 69

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3 Maintenance
3.0.1 Introduction
3: Maintenance
3.0.1 Introduction
General This chapter contains information on how to maintain the equipment described, i.e. how to
perform the preventive maintenance activities specified in the maintenance schedule for the
same equipment.
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3 Maintenance
3.1.1 Specification of maintenance intervals
3.1: Maintenance schedule
3.1.1 Specification of maintenance intervals
Description The intervals may be specified in different ways depending on the type of maintenance activ-
ity to be carried out and the working conditions of the robot:
• Calendar time: specified in months regardless of whether the robot system is run or
not
• Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.
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3 Maintenance
3.1.2 Maintenance schedule
3.1.2 Maintenance schedule
General The robot system, consisting of manipulator and controller cabinet, must be maintained reg-
ularly to ensure proper function. The maintenance activities and intervals are specified in the
table below.
Non-predictable situations also give rise to inspections of the robot. Any damages must be
attended to immediately!
The inspection intervals do not specify the life of each component.
Activities and The table below specifies the required maintenance activities and intervals.
intervals
Maintenance
Equipment Interval Detailed in section
activity
Replacement Battery pack, mea- 12-36 mths 1 Replacement of battery pack,
suring system measuring system on page 76
Replacement Signal cabling, 12,000 hrs Replacement of signal cabling,
upper arm (option upper arm (option 042) on page
042) 138
Inspection Mechanical stop, Regularly 3 Inspection of mechanical stop,
axis 1 axis 1 on page 74
Change Oil, gearbox axis 4 12,000 hrs 2 Oil change, gearbox axis 4 on
page 84
Change Oil, gearbox axes 5 12,000 hrs 2 1. Oil change, gearbox axis 5
and 6 and 6 (all robot versions
except IRB 4400/L10) on
page 86
2. Oil change, gearbox axis 5
and 6 (IRB 4400/L10 only)
on page 89
1. The battery is used as a back-up when the robot system is switched off. Therefore, the
life of a lithium battery depends on how frequently the power to the system is switched
off and also if the environment temperature is higher than recommended operating
temperature. The life varies from 12 - 36 mths, depending on current conditions. An
alert is given on the TPU when the battery is nearly discharged and it must then be
replaced within a month.
2. The gearboxes are lubricated for life, which corresponds to 40,000 hours of operation
if the robot is operating with an ambient temperature of less than 40°C. If the tempera-
ture is higher, the oil should be changed!
3. Must be replaced if bent!
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3 Maintenance
3.2.1 Inspection of mechanical stop, axis 1
3.2: General maintenance activities
Location of The mechanical stop on axis 1 is located on the frame as shown in the figure below.
mechanical stop
xx0300000182
A Mechanical stop pin, axis 1

B Set screw
Required
equipment
Mechanical stop, axis 1 3HAB 3647-1
Standard toolkit 3HAC 17594-1 The contents are
defined in section Stan-
dard toolkit in the Prod-
uct manual, reference
information.
Other tools and procedures These procedures
may be required. See refer- include references to
ences to these procedures in the tools required.
the step-by-step instructions
below.
Inspection The procedure below details how to inspect the mechanical stop on axis 1
Warning!
result in burns!
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3 Maintenance
Warning!
If the mechanical stop has been deformed after a hard collision, it must be replaced!

1. Check regularly that the pin is not bent or dam- Removal/refitting of the mechan-
aged in any other way. ical stop is detailed in section
If bent/damaged, the pin must be replaced by a Replacement of mechanical stop
new one. pin, axis 1 on page 178.
2. Also check that the pin is properly attached.
3HAC 022032-001 Revision - 75

3 Maintenance
3.2.2 Replacement of battery pack, measuring system
Location of The battery pack is fit to the serial measurement unit, located inside the base. To access the
battery pack unit and battery pack, the rear cover plate shown in the figure below must be removed.
xx0300000106
A Rear cover plate
Required
equipment
Battery pack 4944 026-4 Rechargeable nickel-
cadmium battery.
Battery pack 3HAC 16831-1 Lithium battery.
in section Standard tool-
kit in the Product manual,
may be required. See refer- include references to the
ences to these procedures tools required.
in the step-by-step instruc-
tions below.
Replacement, The procedure below details how to replace the battery pack in the serial measurement unit.
battery pack
Danger!
Follow these instruction to prevent the unit to be damaged from ESD:
The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are grounded through a special ESD wrist bracelet or similar.
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3 Maintenance

1. Set the robot to the MOTORS OFF operating
mode.
This way the robot does not need to be calibrated
after the battery change.
2. Remove the rear cover plate from the base. Shown in the figure Location of
battery pack on page 76.
3. Loosen the battery terminals from the serial mea-
suring board and cut the clasps that keep the bat-
tery pack in place.
4. Remove the old battery pack.
5. Fit a new battery pack with two clasps and con- Part no. is specified in Required
nect the terminals to the serial measuring board. equipment on page 76.
6. The rechargeable nickel-cadmium battery takes
36 hours to recharge; the mains supply must be
switched on during this time.
3HAC 022032-001 Revision - 77

3 Maintenance
3.2.3 Cleaning of manipulator
3.2.3 Cleaning of manipulator
General Depending on the protection class, different methods of cleaning the manipulator are allowed.
This section describes how to clean
• the Standard version
• the Foundry version
Standard version The protection class is IP54.

The exterior of the robot should be cleaned as required. Use a vacuum cleaner or wipe it with
a cloth. Do not use compressed air and harsh solvents that can damage the sealing joints,
bearings, lacquer or cabling.
Foundry version The protection class is IP 67, which means that the manipulator is watertight.
Equipment Requirements
Steam cleaner • water pressure at nozzle: max. 2500 kN/m 2 (25 bar)
• type of nozzle: fan jet, min. 45°spread
• flow: max. 100 litres/min
• distance from nozzle to encapsulation: min. 0.4 m
• water temperature: max. 80°C
High pressure water cleaner • fan jet nozzle should be used, min. 45°spread
• max. water pressure on enclosures: 50 kN/m 2 (0.5
bar)
• flow: max. 100 litres/min
Do’s and don’ts! The section below specifies some special considerations when cleaning the manipulator.
Always!
• Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
• Always check that all protective covers are fitted to the robot before cleaning!
Never!
• Never point the water jet at bearing seals, contacts, and other seals!
• Never spray from a distance closer than 0.4 m!
• Never remove any covers or other protective devices before cleaning the robot!
• Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
• Although the manipulator is watertight, avoid spraying connectors and similar items
with a high pressure cleaner!
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3 Maintenance
3.3.1 Oil in gearbox unit, axis 1-2-3
3.3: Change and checking of oil
3.3.1 Oil in gearbox unit, axis 1-2-3
General The oil in the gearbox unit, axis 1-2-3, is normally not changed. This section specifies the oil
permitted in the unit.
Oil in gears, IRB

4400/45, /60, /L30,
/L10 Gear... Art. no. Volume Note
Axis 1 1171 2016-604 8,200 ml
Axis 2-3 1171 2016-604 5,800 ml
The lubricating oil specified above corresponds to:

• Mobile Gearlube X 320
• Mobilgear 632
Oil in gears, IRB

4400/FS
Gear... Art. no. Volume Note
Axis 1 1171 2016-604 10,000 ml
Axis 2-3 1171 2016-604 6,000 ml
The lubricating oil specified above corresponds to:

• Mobile Gearlube X 320
• Mobilgear 632
3HAC 022032-001 Revision - 79

3 Maintenance
3.3.2 Inspection of oil levels
Location of oil The oil plug, filling for the gearbox unit, axes 2 and 3, is located as shown in the figure below.
plugs, axes 2 and The figure shows the location of the axis-2-side and is the same on the opposite side.
3
A
xx0300000331
A Oil plug, filling
Location of oil The axis 4 gearbox has one oil plug for draining and one oil plug for filling, located as shown
plugs, axis 4 in the figure below.
x
A
B
x-x
B
xx0300000220
A Upper oil plug, filling

B Lower oil plug, draining
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3 Maintenance
Location of oil The wrist unit has two oil plugs for draining and one oil plug for filling, located as shown in
plugs, axes 5 and the figure below.
6 (all robot ver-
sions except IRB B
4400/L10)
A
xx0300000223
A Oil plug, draining (2 pcs, the other oil plug not shown in figure)
B Oil plug, filling (also used for draining)
Location of oil The wrist unit has one oil plug for draining the oil and one oil plug for filling, located as
plugs, axes 5 and shown in the figure below. The oil plug for filling is also used as an air inlet when draining
6 (only IRB 4400/ the oil.
L10)
xx0300000118
A Oil plug, draining

B Oil plug, filling (also used as air inlet when draining)
Required
equipment
erence information .
3HAC 022032-001 Revision - 81

3 Maintenance

Inspection, oil The procedure below details how to inspect the oil level of the gearbox unit, axes 2-3.
level axis 2-3

1. Remove the oil plug, filling . Shown in the figure Location of oil
plugs, axes 2 and 3 on page 80.
2. Measure the oil level from the oil plug hole. The oil must cover at least half of the
Required oil level: 225 mm ±25 mm. lower arm bearing!
3. Fill or drain, if necessary. Type of oil is detailed in section Oil in
gearbox unit, axis 1-2-3 on page 79.
4. Clean and refit the oil plug.
Inspection, oil The procedure below details how to inspect the oil level of the gearbox, axis 4.
level axis 4
Warning!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!
Warning!
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!

1. Move the upper arm to a horizontal position (cal-
ibration position).
2. Remove the upper oil plug, filling . Shown in the figure Location of
oil plugs, axis 4 on page 80.
3. Required oil level: 4 mm to the edge of the oil
plug hole.
4. Fill with lubricating oil , if necessary. Type of oil is detailed in section
Oil change, gearbox axis 4 on
page 84.
5. Refit the oil plug.
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3 Maintenance
Inspection, oil The procedure below details how to inspect the oil level of wrist unit, axis 5 and 6 for all robot
level axis 5 and 6 versions except IRB 4400/L10.
(all robot ver-
sions except IRB
4400/L10) Step Action Note/Illustration
1. Move the robot to the calibration position.
2. Remove one of the oil plugs, draining at the rear Shown in the figure Location of
of the wrist. oil plugs, axes 5 and 6 (all robot
versions except IRB 4400/L10)
on page 81.
3. Required oil level: on level with the edge of the oil
plug hole.
4. Fill with lubricating oil , if necessary Type of oil is detailed in section
Oil change, gearbox axis 5 and 6
(all robot versions except IRB
4400/L10) on page 86.
Inspection, oil The procedure below details how to inspect the oil level of wrist unit, axis 5 and 6 for robot
level axis 5 and 6 version IRB 4400/L10.
(IRB 4400/L10)

1. Move the robot to a position where the upper arm
is close to horizontal and axis 4 in the calibration
position.
2. Remove the oil plug, filling from the side of the Shown in the figure Location of
wrist. oil plugs, axes 5 and 6 (only IRB
4400/L10) on page 81
3. Required oil level: on level with the edge of the oil
plug hole.
4. Fill with lubricating oil , if necessary. Type of oil is detailed in section
(IRB 4400/L10 only) on page 89.
3HAC 022032-001 Revision - 83

3 Maintenance
3.3.3 Oil change, gearbox axis 4
Location of oil The axis 4 gearbox has one oil plug for draining and one oil plug for filling, located as shown
plugs in the figure below.
x
A
B
x-x
B
xx0300000220
A Upper oil plug, filling

B Lower oil plug, draining
Required
equipment
Lubricating oil 3HAC 0860-1 Optimol Optigear BM 100
Volume: 3,400 ml.
erence information.
Oil collecting vessel Capacity: 4,000 ml.
Draining The procedure below details how to drain the oil from the gearbox, axis 4.
Tip!
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
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3 Maintenance
Warning!

1. Move the arms backward and the upper arm to a
nearly vertical position.
2. Remove the lower oil plug, draining and drain the Shown in the figure Location of
oil into an oil collecting vessel. oil plugs on page 84.
Capacity of the oil collecting ves-
sel is specified in Required
equipment on page 84.
Filling The procedure below details how to refill the oil to the gearbox, axis 4.
Note!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may differ from the specified amount, depending on how much
oil has previously been drained from the gearbox.
Warning!
Warning!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely

1. Move the upper arm to a vertical position
(rear end upwards).
2. Remove the upper oil plug, filling . Shown in the figure Location of oil plugs
on page 84.
3. Fill the gearbox with lubricating oil . Amount and art. no. is specified in
Required equipment on page 84.
Correct oil level is specified in section
Inspection of oil levels on page 80.
3HAC 022032-001 Revision - 85

3 Maintenance
3.3.4 Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10)
Location of oil The wrist unit has two oil plugs for draining and one oil plug for filling, located as shown in
plugs the figure below.
xx0300000223
A Oil plug, draining (2 pcs, the other oil plug not shown in figure)
B Oil plug, filling (also used for draining)
Required
equipment
Volume: 3,400 ml
erence information.
Oil collecting vessel Capacity: 4,000 ml
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3 Maintenance
Draining oil The procedure below details how to drain the oil from the wrist unit (axis 5 and 6).
Tip!
Warning!

1. Move the upper arm to a horizontal position and
turn axis 4 to the calibration position.
2. Turn axis 4 135°.
3. Remove the lower oil plug, draining at the rear of Shown in the figure Location of
the wrist. oil plugs on page 86.
Capacity of oil collecting vessel
is specified in Required equip-
ment on page 86.
4. Remove the other oil plug, draining.
5. Move axis 3 up -15°and let the oil run out for a
couple of minutes.
6. Turn axis 4 so that the oil plug, filling is facing Shown in the figure Location of
downwards. oil plugs on page 86.
7. Remove the oil plug, axis 5 to drain the oil.
8. Move axis 3 down to 0°.
9. Move axis 4 backwards and forwards a couple of
times to drain all the oil.
10. Clean and refit the both oil plugs, draining .
Filling oil The procedure below details how to fill oil to the wrist unit (axis 5 and 6).
Note!
Warning!
Warning!
3HAC 022032-001 Revision - 87

3 Maintenance

1. Move the upper arm to a horizontal posi-
tion and turn axis 4 to calibration position.
2. Turn axis 4 so that the oil plug, filling is Shown in the figure Location of oil plugs
facing upwards. on page 86.
3. Fill the wrist with lubricating oil through Art. no. and amount is specified in
the oil plug hole, filling. Required equipment on page 86.
Fill in intervals so that the oil runs into the Correct oil level is specified in section
wrist. Inspection of oil levels on page 80.
4. Clean and refit the oil plug, filling.
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3 Maintenance
3.3.5 Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only)
Location of oil The wrist unit has one oil plug for draining the oil and one oil plug for filling, located as
plugs shown in the figure below. The oil plug for filling is also used as an air inlet when draining
the oil.
xx0300000118
A Oil plug, draining

B Oil plug, filling (also used as air inlet when draining)
Required
equipment
Volume: 800 ml
Oil collecting vessel Capacity: 1000 ml
3HAC 022032-001 Revision - 89

3 Maintenance
Draining oil The procedure below details how to drain the oil from the wrist unit (axis 5 and 6), robot
version IRB 4400/L10.
Tip!
Warning!

1. Move the upper arm to a horizontal position
and turn axis 4 to the calibration position.
2. Remove the oil plug, draining in the wrist. Shown in the figure Location of oil
plugs on page 89.
3. Turn axis 4 to a position where the oil plug, Shown in the figure Location of oil
draining is faced downwards and drain the oil plugs on page 89.
into an oil collecting vessel . Capacity of vessel is specified in
Also remove the oil plug, filling , in order to use Required equipment on page 89.
it as an air inlet.
4. Turn axis 4 another 90°to allow the remaining
oil to be drained.
5. Clean and refit the oil plug, draining.
Filling oil The procedure below details how to fill oil to the wrist unit (axis 5 and 6), robot version IRB
4400/L10.
Note!
Warning!
Warning!
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3 Maintenance

1. Move the upper arm to a horizontal position
and turn axis 4 to the calibration position.
2. Fill the wrist with lubricating oil through the Art. no. and amount are specified in
oil plug hole, filling. Required equipment on page 89.
Correct oil level is specified in section
Inspection of oil levels on page 80.
3. Clean and refit the oil plug, filling.
3HAC 022032-001 Revision - 91

3 Maintenance
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4 Repair
4.0.1 Introduction
4: Repair
4.0.1 Introduction
Definitions This chapter details all repair activities recommended for the manipulator and any external
units of the manipulator.
It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refit-
ting of a certain component on the manipulator. Each unit contains all information required
to perform the activity, e.g. spare parts numbers, required special tools and materials.
The chapter is divided into:
• Removal/refitting/replacement procedures for all the spare parts on the manipulator
• Remaining procedures for all the spare parts in e.g. the manipulators external units, if
any.
3HAC 022032-001 Revision - 93

4 Repair
4.1.1 Performing a leak-down test
4.1: General procedures
4.1.1 Performing a leak-down test
General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equip-
ment
Leakdown tester 3HAC 0207-1
Leak detection spray
Procedure

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

Grease 3HAB 3537-1 Used to grease the bearings, if not specified other-
wise.
Assembly of all Follow the instructions below when mounting a bearing on the manipulator.
bearings
1. To avoid contamination, let a new bearing remain in its wrapping until it is time for
fitting.
2. Ensure that all parts included in the bearing fitting are free from burrs, grinding
waste and other contamination. Cast components must be free from foundry
sand.
3. Bearing rings, inner rings and roller elements must under no circumstances be
subjected to direct impact. Furthermore, the roller elements must not be exposed
to any stresses during the assembly work.
Assembly of Follow the previous instructions for assembly of all bearings, when mounting a tapered bear-
tapered bearings ing on the manipulator.
In addition to those instructions, the procedure below must be carried out to enable the roller
elements to adjust to the correct position against the race flange.
1. Tension the bearing gradually until the recommended pre-tension is achieved.
2. Note! The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
3. Make sure the bearing is properly aligned, as this will directly affect the lifespan
of the bearing.
Greasing of The bearings must be greased after assembly, according to instructions below:
bearings • The bearings must not be completely filled with grease. However, if space is available
beside the bearing fitting, the bearing may be totally filled with grease when mounted,
as excessive grease will be pressed out from the bearing when the robot is started.
• During operation, the bearing should be filled to 70-80% of the available volume.
• Ensure that grease is handled and stored properly, to avoid contamination.
Grease the different types of bearings as detailed below:
• Grooved ball bearings must be filled with grease from both sides.
• Tapered roller bearings and axial needle bearings must be greased in the split condi-
tion.
3HAC 022032-001 Revision - 95

4 Repair
4.1.3 Mounting instructions for seals
General This sections details how to mount different types of seals to the manipulator.
Equipment

Grease 3HAB 3537-1 Used to lubricate the seals.
Rotating seals The procedure below details how to fit rotating seals.
Caution!
Please observe the following before commencing any assembly of seals:
Protect the sealing surfaces during transport and mounting.
Keep the seal in its original wrappings or protect it well before actual mounting.
The fitting of seals and gears must be carried out on clean workbenches.
Use a protective sleeve for the sealing lip during mounting, when sliding over threads, key-
ways, etc.
Step Action Note

1. Check the seal to ensure that:
• the seal is of the correct type (provided with cut-
ting edge).
• there is no damage to the sealing edge (feel with
a fingernail).
2. Inspect the sealing surface before mounting. If scratches
or damage are found, the seal must be replaced, as it may
result in future leakage.
3. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in
early as there is a risk of dirt and foreign particles adher- Equipment on page 96.
ing to the seal.)
Fill the space between the dust tongue and sealing lip to
2/3 with grease. The rubber coated external diameter
must also be greased, unless otherwise specified.
4. Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.
96 Revision - 3HAC 022032-001

4 Repair
Flange seals and The procedure below details how to fit flange seals and static seals.
static seals
Step Action Note

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

1. Ensure that the correct o-ring size is used.
2. Check the o-ring for surface defects, burrs, Defective o-rings may not be used.
shape accuracy, etc.
3. Check the o-ring grooves. Defective o-rings may not be used.
The grooves must be geometrically correct
and free from pores and contamination.
4. Lubricate the o-ring with grease.
5. Tighten the screws evenly when assembling.
3HAC 022032-001 Revision - 97

4 Repair
4.2.1 Removal of cable harness, axes 1-3
4.2: Complete robot
Location of cable The cable harness of axes 1-3 is located throughout the axis 1 of the manipulator as shown in
harness, axes 1-3 the figure below. Also see the following figure for the view X-X.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information .
X X
B
xx0300000111
A Rear cover plate

B Connectors at the base. Connectors at the rear cover plate: R1.MP,
R1.SMB, R1.CP/CS, R2.MP4-6. Brake release connectors: R2.BU,
R2.BU1-3, R2.BU4-6. Connectors at serial measurement unit: R2.SMB,
R2.FB1-3, R2.FB4-6.
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4 Repair
Location of cable The cable guides in the middle of axis 1 are located as shown in the figure below.
harness, view X-X
D
H G
C
E
X-X
xx0300000110
C Connection box, motor 1. Connectors at motor 1: R3.MP1, R3.FB1.

D Connection box, motor 2. Connectors at motor 2: R3.MP2, R3.FB2.
E Connection box, motor 3. Connectors at motor 3: R3.MP3, R3.FB3.
G Cable guides in the middle of axis 1
H Protection plate
Required
equipment
Standard toolkit 3HAC 17594-1 The contents are defined in section
Standard toolkit in the Product manual,
reference information !
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference information.
3HAC 022032-001 Revision - 99

4 Repair
Removal, cabling The procedure below details how to remove the cable harness from the axes 1-3.
axes 1-3
Warning!
result in burns!
Caution!
The cable packs are sensitive to mechanical damage! They must be handled with care, espe-
cially the connectors, in order to avoid damaging them!
Caution!
Keep the connectors clean during removal/refitting procedures of the cabling! Make sure they
are not contaminated with e.g. grease from the manipulator.

1. Remove the rear cover plate . Shown in the figure Location of cable
harness, axes 1-3 on page 98.
2. Remove the serial measurement unit. Removal detailed in section Removal,
serial measurement unit on page 174.
3. Loosen the connectors R1.MP1, R2.FB1- Shown in the figure Location of cable
3, R2.BU, R2.BU1-3 . Also loosen the harness, axes 1-3 on page 98.
earth connections.
4. Cut all the ties around bundle.
5. Remove the cable bracket inside the base.
6. Remove the cable guides and the protec- Shown in the figure Location of cable
tion plate in the middle of axis 1. harness, view X-X on page 99.
7. Remove the covers from the connections
boxes for the motors in axes 1-2-3.
8. Loosen all the connectors to the motors of Shown in the figure Location of cable
axes 1-2-3. harness, view X-X on page 99.
9. Remove the connection boxes from the
motors 1-2-3.
10. Feed the cabling up through the middle of
axis 1 and remove the complete cabling.
Tip! Gather the loose cabling and connec-
tors into a package with tape in order to
protect the connectors and make the
cabling easier to handle.
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4 Repair
4.2.2 Refitting of cable harness, axes 1-3
Location of cable The cable harness of axes 1-3 is located throughout the axis 1 of the manipulator as shown in
harness, axes 1-3 the figure below. Also see the following figure for the view X-X.
X X
B
xx0300000111
A Rear cover plate

R1.SMB, R1.CP/CS, R2.MP4-6. Brake release connectors: R2.BU,
R2.BU1-3, R2.BU4-6. Connectors at serial measurement unit: R2.SMB,
R2.FB1-3, R2.FB4-6.
3HAC 022032-001 Revision - 101

4 Repair
harness, view X-X
D
H G
C
E
X-X
xx0300000110

H Protection plate
Required
equipment
Cable harness, axes 1-3 3HAC 4137-1
Gasket 3HAC 4432-1 Between the motor and the
connection box, axes 1, 2
and 3.
Replace if damaged.
ence information !
below.
102 Revision - 3HAC 022032-001

4 Repair

Circuit Diagram See chapter Circuit diagram
Calibration Pendulum Details how to calibrate the
Instruction robot with the pendulum.
Art. no. is specified in sec-
tion Document references
Refitting, cabling The procedure below details how to refit the cable harness to axes 1-3.
axes 1-3
Warning!
result in burns!
Caution!
Caution!

1. Feed the cable harness, axes 1-3 through the Art. no. is specified in Required
protection plate and down through the middle of equipment on page 102.
axis 1.
Tip! Gather the loose cabling and connectors
into a package with tape in order to protect the
connectors and make the cabling easier to han-
dle.
2. Refit the connection boxes to the motors 1-2-3. Part no. is specified in Required
Replace the gaskets if they are damaged. equipment on page 102.
3. Reconnect the connectors in the motors 1-2-3. Shown in the figure Location of
cable harness, view X-X on
page 102.
4. Refit the cable guide and the protection plate in Shown in the figure Location of
the middle of axis 1. cable harness, view X-X on
page 102.
5. Secure the cabling with straps, according to fold- See the Foldouts in the Product
out 3. manual, reference information .
6. Refit the cable bracket inside the base.
3HAC 022032-001 Revision - 103

4 Repair

7. Reposition the cabling inside the base according See the Foldouts in the Product
to foldout 4. manual, reference information .
8. Reconnect all the connectors at the base.
9. Refit the serial measurement unit. Detailed in Refitting, serial mea-
surement unit on page 175.
10. Refit the rear cover plate . Shown in the figure Location of
cable harness, axes 1-3 on
page 101.
11. Refit the covers of the connection boxes.
12. Recalibrate the robot! Calibration is detailed in chap-
ter Calibration on page 219.
If the robot is calibrated with the
Calibration Pendulum, follow
the Calibration Pendulum
Instruction , enclosed with the
calibration toolkit. Art. no. for
the instruction is specified in
section Document references in
the Product manual, reference
information .
Danger!
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel are standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
104 Revision - 3HAC 022032-001

4 Repair
Location of cable The cable harness of axes 4-6 is located throughout the manipulator as shown in the figure
harness, axes 4-6 below. Also see the following figure for the view X-X.
F
I
J
X X
B
xx0300000112
A Rear cover plate

R1.SMB, R1.CP/CS (customer connection), R2.MP4-6. Brake release
connectors: R2.BU, R2.BU1-3, R2.BU4-6. Connectors at serial measure-
ment unit: R2.SMB, R2.FB1-3, R2.FB4-6.
F Connection box, motor 4, 5 and 6. Connectors to the motors at upper arm:
R3.MP4, R3.MP5, R3.MP6, R3.FB4, R3.FB5, R3.FB6. Customer connec-
tions: R2.CP, R2.CS.
I Cable bracket inside the lower arm
J Cable bracket at the upper arm
3HAC 022032-001 Revision - 105

4 Repair
harness, view X-X
D
H G
C
E
X-X
xx0300000110

H Protection plate
Required
equipment
Standard toolkit 3HAC 17594-1 The contents are defined in section
Standard toolkit in the Product manual,
reference information !
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference information .
106 Revision - 3HAC 022032-001

4 Repair
Removal, cabling The procedure below details how to remove the cable harness from the axes 4-6.
axes 4-6
Warning!
result in burns!
Caution!
Caution!

1. Remove the cover of the connection box for
motors 4-5-6.
2. Remove the rear cover plate. Shown in the figure Location of cable
3. Remove the serial measurement unit. Detailed in section Removal, serial
measurement unit on page 174.
4. Loosen the connectors R2.MP4-6, R2.FB4- Shown in the figure Location of cable
6, R2.BU4-6, R1.CP/CS. Also loosen the harness, axes 4-6 on page 105.
earth connections.
5. Cut all the straps around the bundle.
6. Remove the cable bracket inside the base.
7. Remove the cable guides and protection Shown in the figure Location of cable
plate in the middle of axis 1. harness, view X-X on page 106.
8. Loosen the cable brackets (A) between
gearboxes 2 and 3 and cut the strap around
them.
A
xx0300000113
3HAC 022032-001 Revision - 107

4 Repair

9. Feed the cabling and air hose, if any, up
through axis 1.
Tip! Gather the loose cabling and connec-
tors into a package with tape in order to pro-
tect the connectors and make the cabling
easier to handle.
10. Loosen the cable bracket inside the lower Shown in the figure Location of cable
arm and undo the two screws. harness, axes 4-6 on page 105.
11. Loosen the cable bracket at the upper arm . Shown in the figure Location of cable
12. Loosen the all the connectors to the motors Shown in the figure Location of cable
at the upper arm and customer connections, harness, axes 4-6 on page 105.
if any.
13. Remove the connection box together with
the cabling.
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4 Repair
Location of cable The cable harness of axes 4-6 is located throughout the manipulator as shown in the figure
harness, axes 4-6 below. Also see the following figure for the view X-X.
F
I
J
X X
B
xx0300000112
A Rear cover plate

R1.SMB, R1.CP/CS (customer connection), R2.MP4-6. Brake release
connectors: R2.BU, R2.BU1-3, R2.BU4-6. Connectors at serial measure-
ment unit: R2.SMB, R2.FB1-3, R2.FB4-6.
F Connection box, motor 4, 5 and 6. Connectors to the motors at upper arm:
R3.MP4, R3.MP5, R3.MP6, R3.FB4, R3.FB5, R3.FB6. Customer connec-
tions: R2.CP, R2.CS.
I Cable bracket inside the lower arm
J Cable bracket at the upper arm
3HAC 022032-001 Revision - 109

4 Repair
harness, view X-X
D
H G
C
E
X-X
xx0300000110

H Protection plate
Required
equipment
Cable harness, axes 4-6 3HAC 7822-1
Gasket 3HAC 3676-1 3 pcs
Between the motor and the
connection box.
Replace if damaged.
erence information !
110 Revision - 3HAC 022032-001

4 Repair

Circuit Diagram See chapter Circuit dia-
gram in the Product man-
ual, reference information .
Calibration Pendulum Details how to calibrate the
Instruction robot with the calibration
pendulum.
Art. no. is specified in sec-
Connection box, The figure below shows the location of the motors, connectors and cabling in the upper arm
upper arm connection box.
D
B1 A
A2
A1 C1
F
B2
C2 E
C
xx0300000116
A Axis 4 motor
A1 Connector R3.MP4
A2 Connector R3.FB4
B Axis 5 motor
B1 Connector R3.MP5
B2 Connector R3.FB5
C Axis 6 motor
C1 Connector R3.MP6
C2 Connector R3.FB6
D Protection plate
E Cable strap, indoor
F cable strap, outdoor
3HAC 022032-001 Revision - 111

4 Repair
Refitting, cabling The procedure below details how to refit the cable harness to the axes 4-6.
axes 4-6
Warning!
result in burns!
Caution!
Caution!

1. Check the position of the three gaskets , Part no. is specified in Required
located between the motors and the con- equipment on page 110.
nection box. Replace them if damaged.
2. Refit the connection box.
Make sure the gaskets are seated properly!
3. Reconnect all the connectors and reposition Connectors and correct positioning
the cabling inside the connection box using are shown in the figure Connection
straps. box, upper arm on page 111.
4. Refit the protection plate in the connection Shown in the figure Connection box,
box. upper arm on page 111.
5. Run the cabling through the lower arm.
6. Refit the cable bracket at the upper arm. Shown in the figure Location of cable
7. Refit the cable bracket inside the lower arm. Shown in the figure Location of cable
8. Feed the cabling through the protection Shown in the figure Location of cable
plate and down through the axis 1. harness, view X-X on page 110.
9. Refit the cable brackets (A) between the
gearboxes of axes 2 and 3 and strap the
cabling.
A
xx0300000113
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4 Repair

10. Refit the cable bracket inside the base.
11. Put straps around the bundle and position See the Foldout chapter .
the cabling at the base according to foldout
4.
12. Reconnect all the connectors at the base.
13. Refit the serial measurement unit. Detailed in Refitting, serial measure-
ment unit on page 175.
14. Refit the rear cover plate. Shown in the figure Location of cable
15. Refit the cover of the connection box in the
upper arm.
16. Recalibrate the robot! Calibration is detailed in chapter Cal-
ibration on page 219.
If the robot is calibrated with the Cal-
ibration Pendulum, follow the Cali-
bration Pendulum Instruction ,
enclosed with the calibration toolkit.
Art. no. for the instruction is specified
in section Document references in
the Product manual, reference infor-
mation .
Danger!
it is vital that:
3HAC 022032-001 Revision - 113

4 Repair
4.2.5 Removal of complete arm system
Location of com- The complete arm system includes the lower arm and the complete upper arm, as shown in
plete arm system the figure below.
A more detailed view of the component and its position may be found in the Foldout section
in the Product manual, reference information!
A
D E
A C
xx0300000143
A Lower arm
B Upper arm
C Attachment screws and friction washers, lower arm
D Parallel arm
E V-ring between lower arm and gearbox axis 3
Required
equipment
kit in the Product man-
ual, reference
information.
tions below.
114 Revision - 3HAC 022032-001

4 Repair
Removal, com- The procedure below details how to remove the complete arm system from the manipulator.
plete arm system
Warning!
result in burns!
Caution!
The complete arm system weighs xx kg! All lifting equipment used must be dimensioned
accordingly!

1. Remove the tie rod. Detailed in section Removal of tie rod
on page 153.
2. Remove the cabling down to axis 1. Detailed in section Removal of cable
3. Move the upper arm into a resting position
against the lower arm.
Lock the upper arm in this position with
securing slings around the lower and
upper arm (A), as shown in the figure to
the right.
Note! If the arms are not properly
secured, the upper arm may move during
the lift and cause a drop of the complete A
arm system.
xx0300000142
4. Unload the weight of the arm system with

lifting slings and a crane.
5. Remove the balancing device. Detailed in section Removal of balanc-
ing device on page 164.
6. Remove the parallel arm. Detailed in section Removal of parallel
arm /Removal of bearing on page 158.
7. Remove the attachment screws and fric- Shown in the figure Location of com-
tion washers, lower arm . plete arm system on page 114.
8. Lift away the complete arm system.
Make sure the upper and lower arm are
properly secured to each other during the
lift.
3HAC 022032-001 Revision - 115

4 Repair
4.2.6 Refitting of complete arm system
Location of com- The complete arm system includes the lower arm and the complete upper arm, as shown in
plete arm system the figure below.
A
D E
A C
xx0300000143
A Lower arm
B Upper arm
C Attachment screws and friction washers, lower arm
D Parallel arm
E V-ring between lower arm and gearbox axis 3
Required
equipment
V-ring 3HAC 3773-11 2 pcs
On both sides of the lower
arm, in the frame.
Grease 3HAB 3537-1 Used to grease sealings
and bearings.
116 Revision - 3HAC 022032-001

4 Repair

Other tools and procedures These procedures include
may be required. See refer- references to the tools
ences to these procedures required.
tions below.
Calibration Pendulum Art. no. is specified in sec-
Instruction tion Document references
Refitting, com- The procedure below details how to refit the complete arm system to the manipulator.
plete arm system
Warning!
result in burns!
Caution!
The complete arm system weighs xx kg! All lifting equipment used must be dimensioned
accordingly!

1. Check and grease both of the V-rings in the Part no. is specified in Required
frame. Replace if damaged. equipment on page 116.
2. Lift the arm system into mounting position.
Make sure the arms are properly secured to each
other (A), as shown in the figure to the right.
xx0300000142
3HAC 022032-001 Revision - 117

4 Repair

3. Secure the arm system to the gearbox axis 2 with 10 pcs, M16x55. Tightening
the attachment screws and friction washers. torque: 260 Nm.
Make sure both V-rings are seated properly! Shown in the figure Location of
complete arm system on page
116.
4. Grease the bearing seating of the parallel arm in
the lower arm, to prevent clicking during opera-
tion.
5. Refit the parallel arm. Detailed in section Refitting of
parallel arm /Refitting of bearing
on page 161.
6. Refit the balancing device. Detailed in section Refitting of
balancing device on page 168.
7. Move the upper arm to a horizontal position with
a crane.
8. Refit the tie rod. Detailed in section Refitting of tie
rod on page 155.
9. Refit the cabling to the upper arm. Detailed in section Refitting of
cable harness, axes 4-6 on page
109.
10. Recalibrate the robot! Calibration with the pendulum is
detailed in Calibration Pendulum
Instruction, enclosed with the
toolkit.
Other calibration is detailed in
section Calibration on page 219.
Danger!
it is vital that:
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4 Repair
4.3.1 Removal of complete upper arm
4.3: Upper arm
Location of upper The complete upper arm includes the wrist unit and is located as shown in the figure below.
arm A more detailed view of the component and its position may be found in the Foldout section
A C
D x
I
J
F
E
H
x-x
xx0300000129
A Upper arm
B Connectors of motors, axes 4, 5 and 6
C Connection box, upper arm
D Calibration plate, axis 3
E VK cover
F KM nut
G Screw
H Bearing
I Sealing ring
J Shaft end
3HAC 022032-001 Revision - 119

4 Repair
Required
equipment
ence information.
Dismounting tool 3HAC 0163-1 Used to pull out the shaft.
below.
Removal, upper The procedure below details how to remove the complete upper arm from the manipulator.
arm
Warning!
result in burns!
Caution!
The complete upper arm weighs xx kg without any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!

1. Move the upper arm to a horizontal position.
2. Secure the weight of the upper arm with lifting
slings and a crane.
3. Remove the tie rod. Detailed in section Removal of
tie rod on page 153.
4. Loosen the connectors of motors, axes 4, 5 and Shown in the figure Location of
6. upper arm on page 119.
5. Remove the connection box, upper arm from the Shown in the figure Location of
motors. upper arm on page 119.
6. Remove the calibration plate, axis 3 . Shown in the figure Location of
upper arm on page 119.
7. Remove the VK covers on both sides of the Shown in the figure Location of
upper arm. upper arm on page 119.
Be careful with the bearing beneath the cover!
Make a hole in the outer edge of the cover and
bend it away.
8. Undo the KM nuts . Shown in the figure Location of
120 Revision - 3HAC 022032-001

4 Repair

9. Remove the screws . Shown in the figure Location of
10. Pull out the shaft with the dismounting tool . Art. no. is specified in Required
Mark the shafts (left and right)! equipment on page 120.
11. Remove the sealings and bearings , if damaged. Shown in the figure Location of
12. Remove the upper arm from the manipulator.
3HAC 022032-001 Revision - 121

4 Repair
4.3.2 Refitting of complete upper arm
Location of upper The complete upper arm includes the wrist unit and is located as shown in the figure below.
A C
D x
I
J
F
E
H
x-x
xx0300000129
A Upper arm
B Connectors of motors, axes 4, 5 and 6
C Connection box, upper arm
D Calibration plate, axis 3
E VK cover
F KM nut
G Screw
H Bearing
I Sealing ring
J Shaft end
Required
equipment
Sealing ring 3HAC 7877-1
Taper roller bearing 3HAA 2103-13
VK cover 3HAC 12165-1
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4 Repair

Shaft end 3HAC 4744-1
Grease 3HAB 3537-1 Used to grease the bear-
ing.
Locking liquid Loctite 243
ence information. .
Mounting tool 3HAB 1463-1 Used to fit the inner ring of
the bearing.
Contains two separate
parts.
De-air tool 3HAC 8704-1 Used to evacuate air when
refitting VK-cover, if the
cover has no grooves for
venting.
erence information..
Refitting, upper The procedure below details how to refit the complete upper arm to the manipulator.
arm
Warning!
result in burns!
Caution!
The complete upper arm weighs xx kg without any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!

1. Fit the sealings and the outer ring of the Shown in the figure Location of upper
bearings in the upper arm, if removed. arm on page 122.
The bearing must be completely filled with Part no. is specified in Required equip-
grease. ment on page 122.
2. Lower the upper arm into mounting posi-
tion.
3HAC 022032-001 Revision - 123

4 Repair

3. Refit both shaft ends. Shown in the figure Location of upper
arm on page 122.
Part no. is specified in Required equip-
ment on page 122.
4. Insert both screws. Shown in the figure Location of upper
arm on page 122.
2 pcs, tightening torque: 470 Nm.
5. If the bearing is removed, the inner ring of Art. no. is specified in Required equip-
the bearing is fitted as follows: ment on page 122.
• Fit the holding-on tool (part A of the
mounting tool ) on the right side of C
the upper arm (seen from behind).
• Fit the inner ring (C) of the bearing
on the left side of the upper arm,
using the press tool (part B of the
mounting tool).
• Remove the holding-on tool and fit
B A
the inner ring also on that side.
xx0300000130
• A: Holding-on tool
• B: Press tool
• C: Inner ring
6. Apply locking liquid on the threads of the Locking liquid specified in Required
KM nut. equipment on page 122
Shown in the figure Required equip-
ment on page 122.
7. Tighten the KM nut...
• on the left side , with torque 95
Nm in order to center the upper
arm
• on the right side first with 105
Nm. Then unscrew the KM nut and
re-tighten it with torque 95 Nm.
Note! This procedure must be performed
within 10 minutes, before the Loctite
begins to harden.
8. Fit new VK covers. Part no. is specified in Required equip-
Note! If the covers have no grooves for ment on page 122.
venting, the air must be evacuated by Shown in the figure Location of upper
using the de-air tool (A) . Also use a clamp arm on page 122.
as an aid in positioning the covers tilted, to
avoid overpressure.
A
xx0300000134
• A: De-air tool, used if the VK-

cover has no grooves for vent-
ing.
124 Revision - 3HAC 022032-001

4 Repair

9. Refit the tie rod. Detailed in section Refitting of tie rod
on page 155.
10. Refit the calibration plate, axis 3. Shown in the figure Location of upper
arm on page 122.
11. Refit the connection box. Shown in the figure Location of upper
arm on page 122.
12. Reconnect the connectors to motors, axes Shown in the figure Location of upper
4, 5 and 6. arm on page 122.
13. Recalibrate the robot! Calibration with the pendulum detailed
in Calibration Pendulum Instruction ,
enclosed with the toolkit.
Other calibration is detailed in section
Calibration on page 219.
Danger!
it is vital that:
3HAC 022032-001 Revision - 125

4 Repair
4.3.3 Removal of wrist unit
Location of wrist The wrist unit is located in the upper arm as shown in the figure below. Removal/refitting
unit procedure differs depending on robot version!
D
C
xx0300000150
A Wrist unit
B O-ring
C Sealing surface between wrist unit and upper arm tube
D Attachment screws and washers
Required
equipment
ence information..
below.
Removal, wrist The procedure below details how to remove the wrist unit from the manipulator.
unit
Note!
This component includes a complete unit comprising motors and gearboxes. It is a replace-
ment unit of complex design and should not normally be serviced on-site. Instead it should
be sent to ABB for service etc.
ABB recommends its customers carry out only the following servicing/repair work on this
unit.
126 Revision - 3HAC 022032-001

4 Repair
Warning!
result in burns!

1. Drain the oil from the wrist unit. Draning detailed in sections Oil change, gear-
box axis 5 and 6 (all robot versions except IRB
4400/L10) on page 86.
2. Remove the attachment screws
and washers, (A).
A
xx0300000148
• Wrist unit on robot version IRB 4400/45,

/60, /L30, /S.
xx0300000149
• Wrist unit on robot version IRB 4400/

L10.
3. Remove the wrist unit from the
upper arm.
3HAC 022032-001 Revision - 127

4 Repair
4.3.4 Refitting of wrist unit
Location of wrist The wrist unit is located in the upper arm as shown in the figure below. Removal/refitting
unit procedure differs depending on robot version!
D
C
xx0300000150
A Wrist unit
B O-ring
C Sealing surface between wrist unit and upper arm tube
D Attachment screws and washers
Required
equipment
Wrist unit 3HAB 8271-1
(IRB 4400/45, /60, /L30, /S)
Wrist unit 3HAB 9398-1
(IRB 4400/L10)
O-ring 2152 2012-541
(IRB 4400/45, /60, /L30, /S)
O-ring 3HAB 3772-12
(IRB 4400/L10)
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4 Repair

Grease 3HAB 3537-1 Used to lubricate the o-
ring groove.
Flange sealing 1234 0011-116 Loctite 574
kit in the Product man-
ual, reference
information..
Measuring tool 3HAB 7887-1 Used when mounting the
wrist unit to robot version
IRB 4400/L10.
ences to these procedures in tools required.
below.
Calibration Pendulum Art. no. is specified in
Instruction section Document refer-
ences in the Product
manual, reference infor-
mation..
Refitting, wrist The procedure below details how to refit the wrist unit to robot versions IRB 4400/45, /60, /
unit IRB 4400/45, / L30, /S
60, /L30, /S
Note!
unit.
Warning!
result in burns!

1. Lubricate the o-ring groove in order to position Part no. is specified in Required
the o-ring . equipment on page 128.
Fit the o-ring to the wrist. Shown in the figure Location of
wrist unit on page 128.
3HAC 022032-001 Revision - 129

4 Repair

2. Apply flange sealing to the surface of the wrist Specified in Required equip-
that will seal against the upper arm tube. ment on page 128.
Sealing surface shown in the fig-
ure Location of wrist unit on
page 128.
3. Refit the wrist with attachment screws and wash-
ers (A).
A
xx0300000148
• A: 8 pcs, M10x35. Tight-

ening torque: 41 Nm.
4. Fill the wrist unit with oil. Detailed in section Oil change,
gearbox axis 5 and 6 (all robot
versions except IRB 4400/L10)
on page 86.
detailed in the Calibration Pen-
dulum Instruction , enclosed
with the toolkit.
Danger!
it is vital that:
Refitting, wrist The procedure below details how to refit the wrist unit to robot version IRB 4400/L10.
unit IRB 4400/L10
Note!
unit.
Warning!
result in burns!
130 Revision - 3HAC 022032-001

4 Repair

1. Lubricate and fit the o-ring to the wrist unit . Part no. is specified in Required
Shown in the figure Location of wrist
unit on page 128.
2. Move the upper arm to a vertical position,
wrist side pointing upwards.
3. Refit the wrist unit. Do not tighten the attach-
ment screws!
4. Release the brakes on axes 5 and 6 (one at a Art. no. is specified in Required
time) and fit the measuring tool at the rear of equipment on page 128.
the motor.
5. Push the wrist to locate the smallest play. Adjustment of play is detailed in sec-
tion Refitting of motors axis 5 and 6 .
B B
xx0300000153
Upper arm seen from front

• A: Gears on drive shaft
• B: Gears on wrist
6. Tighten the attachment screws and washers
(A).
xx0300000149
• A: 6 pcs, M8x30. Tightening

torque: 34 Nm.
7. Check the play by moving axes 5 and 6 by
hand.
8. Fill the wrist unit with oil. Detailed in section Oil change, gear-
box axis 5 and 6 (IRB 4400/L10 only)
on page 89.
3HAC 022032-001 Revision - 131

4 Repair

detailed in the Calibration Pendulum
Instruction , enclosed with the toolkit.
Other calibration is detailed in sec-
tion Calibration on page 219.
Danger!
it is vital that:
132 Revision - 3HAC 022032-001

4 Repair
4.3.5 Replacement of arm house unit, axis 4
Location of arm The arm house unit includes the axis 4 housing and the upper arm tube. It is located as shown
house unit in the figure below.
A B
xx0300000183
A Upper arm tube

B Axis 4 housing
Required
equipment
Arm house unit 3HAC 16670-1 Includes axis 4 hous-
ing, upper arm tube,
motors.
Arm house unit 3HAC 17542-1
(Foundry)
information..
3HAC 022032-001 Revision - 133

4 Repair

below.
Calibration Pendulum Instruc- Art. no. is specified in
tion section Document ref-
erences in the Product
manual, reference
information..
Replacement, The procedure below details how to replace the arm house unit.
arm house unit
Warning!
result in burns!
Caution!
The complete arm house unit weighs 152 kg! All lifting equipment used must be dimensioned
accordingly!

1. Remove the wrist unit. Detailed in section Removal of wrist unit on
page 126.
2. Remove the motors for axes 4, 5 Detailed in section Removal of motor, axes 4,
and 6. 5 and 6 on page 198.
3. Remove the arm house unit. Detailed in section Removal of complete
4. Fit the new arm house unit . Part no. is specified in Required equipment on
page 133.
5. Refit the wrist unit. Detailed in section Refitting of wrist unit on
page 128.
6. Refit the motors for axes 4, 5 and 6. Detailed in sections
• Refitting of motor, axis 4 on page 200
7. Recalibrate the robot! Calibration with the pendulum is detailed in
the Calibration Pendulum Instruction ,
Other calibration is detailed in section Calibra-
tion on page 219.
134 Revision - 3HAC 022032-001

4 Repair
Danger!
it is vital that:
3HAC 022032-001 Revision - 135

4 Repair
4.3.6 Replacement of mechanical stop, axis 4
Location of The mechanical stop of axis 4 is located in the upper arm as shown in the figure below.
mechanical stop A more detailed view of the component and its position may be found in the Foldout section
A
x
C
x
B
A
x-x
xx0300000176
A Mechanical stop axis 4

B Damper axis 4
C Attachment screws, mech stop
Required
equipment
Damper 3HAB 3760-1
information..
below.
136 Revision - 3HAC 022032-001

4 Repair
Warning!
result in burns!
Warning!
Warning!
When the damper is removed from axis 4, the axis does not have a mechanical stop! If the
robot is provided with cabling on the upper arm, the cabling can be damaged when the func-
tion “Resetting the work area for an axis”is used, or if the robot is jogged uncalibrated.
Removal, The procedure below details how to remove the axis 4 mechanical stop from the manipulator.
mechanical stop

1. Remove the mechanical stop by removing its Shown in the figure Location of
attachment screws. mechanical stop on page 136.
2. Rotate axis 4 so that the damper is visible. Shown in the figure Location of
Remove the damper. mechanical stop on page 136.
Refitting, The procedure below details how to refit the axis 4 mechanical stop to the manipulator.
mechanical stop

1. Fit the damper to the axis 4. Shown in the figure Location of
mechanical stop on page 136.
Part no. is specified in Required
2. Apply flange sealing to the stop. Art. no. is specified in Required
3. Fit the mechanical stop to the axis 4 with its Shown in the figure Location of
attachment screws. mechanical stop on page 136.
Part no. is specified in Required
4 pcs, M8x16. Tightening torque:
24 Nm.
3HAC 022032-001 Revision - 137

4 Repair
4.3.7 Replacement of signal cabling, upper arm (option 042)
Location of signal The signal cabling (option 042) runs along the upper arm as shown in the figure below.
cabling, upper
arm A C B
D
xx03000000192
A Wrist bracket
B Upper arm bracket
C Front and rear cable holders
D Plastic hose
Required
equipment
Customer connection axis 4 3HAC 8820-1 Includes signal/power
cabling, necessary
brackets, holders etc.
reference information..
tions below.
Removal, signal The procedure below details how to remove the signal cabling from the upper arm.
cabling upper
arm
Warning!
result in burns!
138 Revision - 3HAC 022032-001

4 Repair

1. Remove the wrist bracket and the upper arm Shown in the figure Location of
bracket from the upper arm. signal cabling, upper arm on
page 138.
2. Remove the front and rear cable holders from Shown in the figure Location of
the tube shaft. signal cabling, upper arm on
page 138.
3. Disconnect the connectors at the rear of the
upper arm.
Refitting, signal The procedure below details how to refit the signal cabling to the upper arm.
cabling upper
arm
Warning!
result in burns!

1. Fit transparent protection tape to the narrow part
of the tube shaft. Remove dirt and grease from
the surface first!
2. Move axis 4 to its calibration position (0°).
3. Refit the wrist bracket to the upper arm. Location of the bracket is shown
in the figure Location of signal
cabling, upper arm on page 138.
xx0300000193
• A: 2 pcs, M8x12.
3HAC 022032-001 Revision - 139

4 Repair

4. Refit the upper arm bracket to the upper arm. Location of the bracket is shown
in the figure Location of signal
cabling, upper arm on page 138.
xx0300000194
• B: 3pcs, M8x12.
5. Slowly rotate axis 4 clockwise to its stop position.
Constantly check that the cables are not fully
extended!
Note! If the cables gets fully extended, stop the
rotation and let out more cable from the rear
cable holder. This is done by loosening the grey
holders and pushing ot the cables by hand.
6. Complete the rotation.
Note! Do not tighten the rear cable holder, leave
it open!
7. First fit the front cable holder around the tube
B
shaft.
Run the black plastic hose through the foot of the
holder.
A
Fit the rear cable holder around the tube shaft in
the same way.
xx0300000197
• A: Plastic hose
• B: Cable holder
Also see the figure Location of
signal cabling, upper arm on
page 138.
8. Move axis 4 from one extreme limit to the other
and back again.
Caution!
Check the cables during movement:

• the cables must not be fully extended!
• the cables and air hose must not touch
any moving parts of the arm!
• the fixing rings must always slide
smoothly with no excessive pulling!
140 Revision - 3HAC 022032-001

4 Repair

9. Adjust the length of the cables by pushing and
pulling the cables through the inner holders,
which are still loose.
Note! When axis 4 is moving, no stretching of
the cables should be felt.
10. Tighten the holders by hand. Do not use tools.
11. Reconnect the connectors at the rear end of the
upper arm.
12. Connect the air hose.
13. Secure the cables and air hose together with
cable straps above the motors.
Danger!
it is vital that:
3HAC 022032-001 Revision - 141

4 Repair
4.3.8 Measuring the play, axis 5
General After reassembly due to repair work or any other reason, the play in axis 5 and 6 must be
checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 5
is detailed below.
Required
equipment
reference information..
Measuring tool, play 3HAC 1611-6
(IRB 4400/45, /60, /L30, /S)
Measuring tool, play 3HAB 6337-1
(IRB 4400/L10)
tions below.
Measurement, The procedure below details how to measure the play of axis 5.
axis 5 Notice that the measuring tool and measuring values differ depending on robot version!
Warning!
result in burns!

1. Move the robot to calibration position and turn the
axis 4 90°.
2. Fit the measuring tool, play to the turning disk. Art. no. is specified in Required
142 Revision - 3HAC 022032-001

4 Repair

3. Apply load F in one direction, as shown in the fig-
ure to the right.
F
Note! Different load and distances for the differ- B C
ent robot versions, as specified to the right!
A
xx0300000186
Values for robot version IRB

4400/45, /60, /L30, /S:
• A: Measuring tool, play
• B: 100mm
• C: 140mm
• F: 200N
4400/L10:
• B: 140mm
• C: 85mm
• F: 40N
4. Remove the load and set the dial indicator to
zero.
3HAC 022032-001 Revision - 143

4 Repair

5. Apply load F in the opposite direction, as shown
B C
in the figure to the right.
A
xx0300000187

4400/45, /60, /L30, /S:
• B: 100mm
• C: 140mm
• F: 200N
4400/L10:
• B: 140mm
• C: 85mm
• F: 40N
6. Remove the load and measure the play by read- The maximum play allowed at
ing the dial indicator. the given distance from the cen-
ter of axis 5 is, for robot version
• IRB 4400/45, /60, /L30, /
S: 0.20mm
• IRB 4400/L10: 0.08mm .
144 Revision - 3HAC 022032-001

4 Repair
General After reassembly due to repair work or any other reason, the play in axis 5 and 6 must be
checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 6
is detailed below.
Required
equipment
information..
(IRB 4400/45, /60, /L30, /S)
(IRB 4400/L10)
ences to these procedures in tools required.
below.
Measurement, The procedure below details how to measure the play in axis 6.
axis 6 Notice that the measuring tool and measuring values differ depending on robot version!
Warning!
result in burns!

1. Fit the measuring tool, play to the turning Art. no. is specified in Required
disk. equipment on page 145.
3HAC 022032-001 Revision - 145

4 Repair

2. Attach a weight (m) at a distance (B) from the
B
wrist flange, in order to avoid the effects of
play on axis 5.
Note! Different weight and distance for the
different robot versions, as specified to the
right!
m
A
xx0300000188
Values for robot version IRB 4400/

45, /60, /L30, /S:
• B: 100mm
• m: 20 kg
L10:
• B: 140mm
• m: 10 kg
3. Apply load F in one direction.
F
Note! Different load and distances for the
B C
different robot versions, as specified to the
right!
A
xx0300000189

45, /60, /L30, /S:
• B: 100mm
• C: 100mm
• F: 100N
L10:
• B: 100mm
• C: 150mm
• F: 40N
4. Remove the load and set the dial indicator to
zero.
146 Revision - 3HAC 022032-001

4 Repair

5. Apply load F in the opposite direction, as
B C
shown in the figure to the right.
A
F
xx0300000190

45, /60, /L30, /S:
• B: 100mm
• C: 100mm
• F: 100N
L10:
• B: 100mm
• C: 150mm
• F: 40N
6. Remove the load and measure the play by The maximum play allowed at the
reading the dial indicator. given distance (B) from the center of
axis 6 is, for robot version
• IRB 4400/45, /60, /L30, /S:
0.15mm
• IRB 4400/L10: 0.2mm .
3HAC 022032-001 Revision - 147

4 Repair
4.4.1 Removal of lower arm
4.4: Lower arm
Location of lower The lower arm is located as shown in the figure below.
E F
B
C
x-x
xx0300000141
A Lower arm
B Attachment screws and friction washers, lower arm
C Calibration plate, axis 2
D Damper
148 Revision - 3HAC 022032-001

4 Repair
E Parallel arm
F V-ring between lower arm and gearbox axis 3
Required
equipment
information.
below.
Removal, lower The procedure below details how to remove the lower arm from the manipulator.
arm
Warning!
result in burns!
Caution!
The lower arm weighs 68 kg! All lifting equipment used must be dimensioned accordingly!

1. Remove the cabling down to axis 1. Detailed in section Removal of cable
2. Remove the complete upper arm. Detailed in section Removal of com-
plete upper arm on page 119.
3. Attach a crane to the lower arm and unload
the weight.
4. Remove the balancing device. Detailed in section Removal of bal-
ancing device on page 164.
5. Remove the parallel arm. Detailed in section Removal of paral-
lel arm /Removal of bearing on page
158.
6. Remove the attachment screws and friction Shown in the figure Location of lower
washers, lower arm. arm on page 148.
7. Remove the lower arm from the manipulator.
3HAC 022032-001 Revision - 149

4 Repair
4.4.2 Refitting of lower arm
Location of lower The lower arm is located as shown in the figure below.
E F
B
C
x-x
xx0300000141
A Lower arm
B Attachment screws and friction washers, lower arm
C Calibration plate, axis 2
D Damper
E Parallel arm
F V-ring between lower arm and gearbox axis 3
150 Revision - 3HAC 022032-001

4 Repair
Required
equipment
Lower arm 3HAC 5955-1
(IRB 4400/45, /60, /L10, /L30)
Lower arm 3HAC 5956-1
(IRB 4400FS)
V-ring 3HAC 3773-11 2 pcs
On both sides of the
lower arm, in the frame.
Grease 3HAB 3537-1 Used to grease seal-
ings and bearings.
information.
below.
manual, reference
information.
Refitting, lower The procedure below details how to refit the lower arm to the manipulator.
arm
Warning!
result in burns!
Caution!
The lower arm weighs 68 kg! All lifting equipment used must be dimensioned accordingly!

1. Move the damper and the calibration Part no. is specified in Required equip-
plate from the old to the new lower arm. ment on page 151.
2. Check and grease both V-rings in the Part no. is specified in Required equip-
frame. Replace if damaged. ment on page 151.
3HAC 022032-001 Revision - 151

4 Repair

3. Lift the lower arm and lower it into
mounting position.
Make sure both V-rings stay seated
properly!
4. Refit the lower arm to the gearbox axis 10 pcs, M16x55. Tightening torque: 260
2 with attachment screws and friction Nm.
washers, lower arm. Shown in the figure Location of lower arm
on page 150.
5. Grease the bearing seating of the paral-
lel arm in the lower arm, to prevent click-
ing during operation.
6. Refit the parallel arm. Detailed in section Refitting of parallel
arm /Refitting of bearing on page 161.
7. Refit the balancing device. Detailed in section Refitting of balancing
device on page 168.
8. Refit the upper arm. Detailed in section Refitting of complete
9. Refit the cabling. Detailed in section Refitting of cable har-
ness, axes 4-6 on page 109.
10. Recalibrate the robot! Calibration with the pendulum is detailed
in the Calibration Pendulum Instruction,
Danger!
it is vital that:
152 Revision - 3HAC 022032-001

4 Repair
4.4.3 Removal of tie rod
Location of tie The tie rod is located as shown in the figure below.
rod A more detailed view of the component and its position may be found in the Foldout section
F G
B
X
D
E
X
C
F G
X-X
xx0300000117
A Tie rod
B Attachment screw
C Washer
D O-ring
E Sealing, outside
F Spherical roller bearing
G Sealing, inside
3HAC 022032-001 Revision - 153

4 Repair
Required
equipment
ence information.
Puller tool 2 pcs
Used to pull out the tie rod
alternately at the upper and
lower end if the tie rod.
below.
Removal, tie rod The procedure below details how to remove the tie rod from the manipulator.
Warning!
result in burns!

1. Lock the upper arm in a horizontal position with
help of a crane or similar.
2. Remove the two attachment screws . Shown in the figure Location of
3. Remove the two washers, o-rings and sealings, Shown in the figure Location of
outside from the tie rod. tie rod on page 153.
4. Insert a screw in each center, to be used as a
support.
5. Use two puller tools to pull out the tie rod, one at
the upper and lower end.
Pull alternately at the upper end and at the lower
end with the puller tools!
6. Remove the bearings if they are to be replaced. The part no. for new bearings is
specified in section Refitting of
154 Revision - 3HAC 022032-001

4 Repair
4.4.4 Refitting of tie rod
Location of tie The tie rod is located as shown in the figure below.
rod A more detailed view of the component and its position may be found in the Foldout section
F G
B
X
D
E
X
C
F G
X-X
xx0300000117
A Tie rod
B Attachment screw
C Washer
D O-ring
E Sealing, outside
F Spherical roller bearing
G Sealing, inside
Required
equipment
Washer 3HAB 3704-1 Replace if damaged.
3HAC 022032-001 Revision - 155

4 Repair

O-ring 3HAB 3772-23
Sealing, outside 3HAC 3297-1
Spherical roller bearing 3HAA 2167-11
Sealing, inside 3HAC 3990-11
Grease 3HAB 3537-1 Used to lubricate the shaft
on the manipulator where
the tie rod is to be refitted.
Locking liquid Loctite 243
ence information.
Press tool 3HAB 1598-1 Used to press in the spher-
ical roller bearing.
Press tool, p-arm 3HAB 1529-1 2 pcs
Used to press on the tie rod
alternately at the upper and
lower end of the tie rod.
below.
Calibration Pendulum Art. no. is specified in Doc-
Instruction ument references in the
Product manual, reference
information.
Refitting, tie rod The procedure below details how to refit the tie rod on to the manipulator.
Warning!
result in burns!

1. If the bearings are to be replaced, fit new spheri- Part/ Art. no. is specified in
cal roller bearings and new sealings, inside to Required equipment on page
the tie rod. 155.
Use the press tool.
2. Lift the tie rod to its mounting site. Make sure the
tie rod is refitted with the correct end up!
156 Revision - 3HAC 022032-001

4 Repair

3. Grease the shaft on the manipulator and refit the Art. no. is specified in Required
tie rod on to the manipulator using two press equipment on page 155.
tools for p-arm.
Press alternately at the upper and lower end with
the press tools!
4. Fit the sealings, outside to the tie rod. Part no. is specified in Required
5. Fit the o-rings to the tie rod. Part no. is specified in Required
6. Refit the washers and attachment screws using Shown in the figure Location of
locking liquid. tie rod on page 155.
Locking liquid specified in
Required equipment on page
155.
7. Recalibrate the robot. Calibration with the pendulum is
dulum Instruction, enclosed with
the calibration toolkit.
Danger!
it is vital that:
3HAC 022032-001 Revision - 157

4 Repair
4.4.5 Removal of parallel arm /Removal of bearing
Location of par- The parallel arm is located on the manipulator, as shown in the figure below.
allel arm The bearing of the parallel arm is shown in the enlarged view.
A more detailed view of the component and its position may be found in the Foldout section!
E F
D
xx0300000128
A Parallel arm
B Attachment screw
C Washer
D V-ring on parallel arm
E Bearing
F Sealing
158 Revision - 3HAC 022032-001

4 Repair
Required
equipment
Lifting tool 3HAB 1412-1 Used to lift the parallel
arm.
tions below.
Removal, parallel The procedure below details how to remove the parallel arm from the manipulator during
arm/bearing repair work. It also details how to remove the bearing from the parallel arm in order to replace
it.
Warning!
result in burns!
Caution!
The parallel arm weighs 70 kg (robot version IRB 4400/45) or 115 kg (robot version IRB
4400/60, IRB 4400/L30, IRB 4400/L10, IRB 4400/S)! All lifting equipment used must be
dimensioned accordingly!

1. Remove the tie rod. Detailed in Removal of tie rod on
page 153.
2. Fit the lifting tool to the parallel arm. Art. no. is specified in Required
Unload the arm with a crane. equipment on page 159.
3. Loosen the attachment screws (A) so that
the cabling can be moved slightly.
xx0300000127
3HAC 022032-001 Revision - 159

4 Repair

4. Remove the 10 attachment screws and the
washer that holds the parallel arm to gearbox
axis 3.
5. Lift away the parallel arm from the manipula-
tor.
6. If they are to be replaced, remove the bear-
ing and sealings from the parallel arm.
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4 Repair
4.4.6 Refitting of parallel arm /Refitting of bearing
Location of par- The parallel arm is located on the manipulator, as shown in the figure below.
allel arm The bearing of the parallel arm is shown in the enlarged view.
E F
D
xx0300000128
A Parallel arm
B Attachment screw
C Washer
D V-ring on parallel arm
E Bearing
F Sealing
3HAC 022032-001 Revision - 161

4 Repair
Required
equipment
V-ring 3HAC 3732-11
Groove ball bearing 3HAC 10905-1
Sealing ring 3HAB 3749-1
Grease 3HAB 3537-1 Used to lubricate the bear-
ings and sealings.
ence information.
Lifting tool 3HAB 1412-1
erence information.
Refitting, parallel The procedure below details how to refit the parallel arm on to the manipulator during repair
arm/bearing work. It also details how to fit a new bearing to the parallel arm as replacement.
Warning!
result in burns!
Caution!
The parallel arm weighs 70 kg (robot version IRB 4400/45) or 115 kg (robot version IRB
4400/60, IRB 4400/L30, IRB 4400/L10, IRB 4400/S)! All lifting equipment used must be
dimensioned accordingly!

1. Fit the new V-ring to the parallel arm. Part no. is specified in Required
2. If the bearing is to be changed: Part no. is specified in Required
1. Heat the new groove ball bearing to equipment on page 162.
170°C.
2. Fit the bearing to the parallel arm.
If the old bearing is kept:
1. Grease the bearing.
162 Revision - 3HAC 022032-001

4 Repair

2. Fit the sealing ring to the bearing. Part no. is specified in Required
3. Refit the washer and the 10 attachment 10 pcs, M16x80, 12.9 quality
screws that hold the parallel arm to the gear- UNBRAKO. Tightening torque: 260
box unit. Nm.
Reused screws may be used, provid-
ing they are lubricated as detailed in
section Screw Joints in the Product
manual, reference information,
before fitting.
4. Move the upper arm to a horizontal position Detailed in section Refitting of tie rod
with a crane (if not already positioned hori- on page 155.
zontal) and refit the tie rod.
5. Reposition the cabling and tighten the cable
attachment screws (A).
xx0300000127

detailed in section Calibration Pendu-
lum Instruction, enclosed with the
calibration toolkit.
Danger!
it is vital that:
3HAC 022032-001 Revision - 163

4 Repair
4.5.1 Removal of balancing device
4.5: Frame and base
Location of bal- The balancing device is located as shown in the figure below.
ancing device A more detailed view of the component and its position may be found in the Foldout section!
A
B D
F
G
xx0300000100
A Balancing device
B Bracket
C Attachment screws, bracket (M12x50)
D Press out hole
E Front screws
F Fork
G End part of shaft
164 Revision - 3HAC 022032-001

4 Repair
Required
equipment
.
Securing front screws M10x40H
H= threaded to the head.
Used to unload the bal-
ancing device before
removal.
Removal, bal- The procedure below details how to remove the balancing device.
ancing device
Warning!
result in burns!
Danger!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Caution!
The balancing device weighs 50 kg!
All lifting equipment used must be dimensioned accordingly!
3HAC 022032-001 Revision - 165

4 Repair

position, as shown in the figure to the right.
A
xx0300000088
• A: Approximately 2º
2. Remove the two securing screws (A),
located at the fork of the balancing device. B
xx0300000089
The fork is shown in the figure Loca-

tion of balancing device on page 164.
166 Revision - 3HAC 022032-001

4 Repair

3. Unload the balancing device by replacing
the two front screws (A) with two securing
front screws .
Unload the device level by fastening the
securing screws parallel with each other.
xx0300000095
Dimension specified in Required

equipment on page 165!
4. Check that the piston is unloaded by mov-
ing it manually.
5. Remove the four attachment screws, Shown in the figure Location of bal-
bracket from the bracket at the right side of ancing device on page 164!
the balancing device (A), seen from above.
A
xx0300000098
6. Remove the bracket from the frame by Shown in the figure Location of bal-
pressing it out using a M10x30 screw in the ancing device on page 164!
press out hole .
7. Remove the balancing device by pushing it
to the side.
Note!
xx0300000099
8. If the balancing device is to be replaced

with a new device, the bracket on the right
side must be removed and fitted to the new
device.
3HAC 022032-001 Revision - 167

4 Repair
4.5.2 Refitting of balancing device
Location of bal- The balancing device is located as shown in the figure below.
ancing device A more detailed view of the component and its position may be found in the Foldout section!
A
B D
F
G
xx0300000100
A Balancing device
B Bracket
C Attachment screws, bracket (M12x50)
D Press out hole
E Front screws
F Fork
G End part of shaft
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4 Repair
Required
equipment
Balancing device 3HAC 15083-1 Includes balancing device
(IRB 4400/45, IRB 3HAC 3702-1
4400/60, IRB 4400L/ Includes cylindrical roller bear-
10, IRB 4400L/30) ing 3HAC 4334-2
Includes front screws 3HAC
6456-1
Balancing device 3HAC 15083-2 Includes balancing device
(IRB 4400FS) 3HAC 3738-1
Includes cylindrical roller bear-
ing 3HAC 4334-2
Includes front screws 3HAC
6456-1
Sealing ring with dust 3HAB 3701-26
lip
Grease 3HAC 3537-1 Udes to lubricate:
• the bearings at the bal-
ancing device brack-
ets (min. 500 ml in
each bearing)
• the sealing at the bal-
ancing device brackets
• the bearing at the bal-
ancing device fork.
Nipple Used to lubricate the bearing
at the balancing device fork.
The lubrication hole is dimen-
sioned M10.
section Standard toolkit .
Press tool, bearing 3HAC 5465-1 Used to fit the cylindrical roller
bearings and the sealings into
the brackets.
Other tools and proce- These procedures include ref-
dures may be erences to the tools required.
required. See refer-
ences to these proce-
dures in the step-by-
step instructions
below.
Refitting, bal- The procedure below details how to refit the balancing device.
ancing device
Warning!
result in burns!
3HAC 022032-001 Revision - 169

4 Repair
Danger!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Caution!
All lifting equipment used must be dimensioned accordingly!

1. Fit the cylindrical roller bearings and sealings Part no. is specified in Required
to the balancing device and brackets if equipment on page 169!
• the balancing device is a new spare
part
• the old bearings/sealings are dam-
aged.
The procedure is detailed in Fitting of cylindri-
cal roller bearing on page 172.
2. Lift the balancing device to its mounting posi-
tion.
If the balancing device is a new spare part, it
must be unloaded as described in Removal,
balancing device on page 165.
Note!
3. Fit the balancing device to the left bracket Shown in the figure Location of bal-
and put the fork into correct position. ancing device on page 168.
4. Refit the right bracket with attachment Shown in the figure Location of bal-
screws, bracket . ancing device on page 168.
4 pcs: M12x50, tightening torque: 82
Nm.
5. Refit the original protection screws in the 2 pcs; MC6S M10x12 8.8 fzb.
press out holes in both the brackets. Shown in the figure Location of bal-
ancing device on page 168.
170 Revision - 3HAC 022032-001

4 Repair

6. Lubricate the bearing at the fork:
1. Remove the two stop screws. B
2. Fill with grease through one of the
lubrication holes, until excessive
grease is forced out through the sec-
ond hole. Use a nipple!
3. Refit the two stop screws.
xx0300000089
• A: Securing screws (2 pcs)

• B: Stop screws, M10 x 40 (2
pcs)
4. Before restoring the balancing device, check The fork is shown in the figure Loca-
that: tion of balancing device on page
• the fork is in position 168.
• the fork does not cover the lubrica-
tion holes of the shaft!
5. Restore the balancing device by removing 2 pcs; MC6S M10x12 8.8 fzb.
the replacement front screws (A) and refitting
the original protection front screws.
xx0300000095
6. Refit the fork to the shaft in the lower arm, by

refitting the two securing screws (A) at the
fork of the balancing device, shown in figure
xx0300000089.
Make sure that the fork does not cover the
lubrication holes of the shaft!
3HAC 022032-001 Revision - 171

4 Repair
Fitting of cylin- The procedure below details how to fit the cylindrical roller bearings onto the balancing
drical roller device shaft and into the frame brackets.
bearing

1. Fit the inner ring of the bearing onto both end Shown in the figure Location of
parts of the balancing devices shaft. balancing device on page 168.
2. Fit the outer ring of the bearing into both brackets Art. no. is specified in Required
with the press tool, bearing. equipment on page 169.
3. Fit the sealing ring with dust lip with the same, but Part no. is specified in Required
turned, press tool, bearing. equipment on page 169.
4. Lubricate the bearing and the sealing with Art. no. and amount specified in
grease. Required equipment on page
169.
Danger!
it is vital that:
172 Revision - 3HAC 022032-001

4 Repair
4.5.3 Replacement of serial measurement unit
Location of serial The serial measurement unit is located inside the base of the manipulator, behind the rear
measurement cover, as shown in the figure below.
unit
xx0300000106
A Rear cover plate
Different ver- There are two versions of the serial measurement unit. They are compatible but designed
sions, serial mea- differently, as shown in the figure below.
surement unit
Note! The battery pack is not compatible between the versions!
A B C D B E
(1) (2)
AT T E NT ION
Obs er ve pr ecautions f or
handling
E le ctrostatic s ensitive
devices
C A
xx0300000105
(1) Old version of serial measurement unit

(2) New version of serial measurement unit
A R2.SMB
B R2.FB4-6
C R2.FB1-3
D Fastening plate
E Battery pack
3HAC 022032-001 Revision - 173

4 Repair
Required
equipment
Serial measurement unit, old 3HAC 14505-1 Includes fastening plate
version 3HAC 3367-1
Battery pack, old version 4944 026-4
Serial measurement unit, 3HAC 16014-1
new version
Battery pack, new version 3HAC 16831-1
Fastening plate, new version 3HAC 17395-1
dard toolkit .
below.
Repair Manual, part 2 (Circuit Art. no. is specified in
Diagram) section Document refer-
ences .
Removal, serial The procedure below details how to remove the serial measurement unit.
measurement
unit
Warning!
result in burns!
Danger!
voltages.

1. Remove the rear cover plate from the base. Shown in the figure Location of
serial measurement unit on page
173.
2. Cut all the straps.
3. Unscrew the nuts that attaches the serial mea-
surement unit inside the base.
4. Remove the serial measurement unit.
174 Revision - 3HAC 022032-001

4 Repair

5. Remove the connectors from the board. The connectors are shown in the
figure Different versions, serial
Refitting, serial The procedure below details how to refit the complete serial measurement unit.
measurement
unit
Danger!
voltages.

1. Refit the connectors to the serial mea- Art. no. is specified in Required equip-
surement unit . ment on page 174.
The connectors are shown in the figure
Different versions, serial measurement
unit on page 173.
2. Refit the serial measurement unit inside
the base using nuts.
3. Strap the cables.
4. Refit the rear cover plate on the base. Shown in the figure Location of serial
5. Recalibrate the robot! Detailed in section Calibration on page
219.
3HAC 022032-001 Revision - 175

4 Repair
4.5.4 Replacement of pushbutton unit for brake release
Location of push- The pushbutton unit for brake release is located in the base of the robot, as shown in the figure
button unit below.
A more detailed view of the component and its position may be found in the Foldout section!
xx0300000106
A Rear cover plate
Connectors on The connectors X8, X9 and X10 are placed on the pushbutton unit as shown in the figure
pushbutton unit below.
X8 X9 X10
xx0300000201
Required
equipment
Pushbutton unit 3HAC 0017-1
in section Standard toolkit.
.
176 Revision - 3HAC 022032-001

4 Repair
Warning!
result in burns!
Danger!
voltages.
Removal, push- The procedure below details how to remove the pushbutton unit from the manipulator.
button unit

1. Secure the manipulator by moving...
• the lower arm to one of its end positions
• the upper arm to its end position.
2. Remove the rear cover plate. Shown in the figure Location of
pushbutton unit on page 176.
3. Remove the connectors X8, X9 and X10 from Shown in the figure Connectors
the pushbutton unit. on pushbutton unit on page 176.
4. Remove the pushbutton unit by removing its
attachment screws.
Refitting of push- The procedure below details how to refit the pushbutton unit to the manipulator.
button unit

1. Refit the new pushbutton unit with its Part no. is specified in Required equip-
attachment screws. ment on page 176.
2. Refit the connectors X8, X9 and X10 to Shown in the figure Connectors on push-
the pushbutton unit. button unit on page 176.
3. Refit the rear cover plate to the base of Shown in the figure Location of pushbut-
the manipulator. ton unit on page 176.
3HAC 022032-001 Revision - 177

4 Repair
4.5.5 Replacement of mechanical stop pin, axis 1
Location of The mechanical stop pin on axis 1 is located on the frame as shown in the figure below.
mechanical stop A more detailed view of the component and its position may be found in the Foldout section!
pin
xx0300000182
A Mechanical stop pin, axis 1

B Set screw
Required
equipment
.
tions below.
Replacement, The procedure below details how to replace the mechanical stop pin on axis 1.
mechanical stop
pin
Warning!
result in burns!
178 Revision - 3HAC 022032-001

4 Repair
Warning!

1. Remove the set screw . Shown in the figure in Location of mechan-
ical stop pin on page 178.
2. Remove the old mechanical stop pin . Shown in the figure in Location of mechan-
ical stop pin on page 178.
3. Refit the new mechanical stop with the Part no. is specified in Required equip-
set screw. ment on page 178.
M10x12
3HAC 022032-001 Revision - 179

4 Repair
4.6.1 Removal of motor, axis 1
4.6: Motors
Location of motor The motor, axis 1, is located as shown in the figure below.
The motor and the drive gear constitute one unit.
A
xx0300000154
A Motor, axis 1
B Connection box with cover
C Attachment screws and washers
Required
equipment
ence information.
Circuit Diagram See chapter Circuit dia-
ual, reference information
180 Revision - 3HAC 022032-001

4 Repair
Removal, motor The procedure below details how to remove the motor, axis 1.
Warning!
result in burns!
Danger!
If a shelf-mounted robot version is not flat mounted, the manipulator can contain a living
force!
Removing the motor from axis 1 may result in movement of the axis, because the brake is
released.
To avoid this, move the robot into normal calibration position or move axis 1 to get the lowest
location of the center of gravity for the upper arm.

1. Remove the cover of the connection box . Shown in the figure Location of
motor on page 180.
2. Disconnect all the connectors in the motor.
3. Remove the connection box . Shown in the figure Location of
motor on page 180.
4. Remove the attachment screws and washers of Shown in the figure Location of
the motor. motor on page 180.
Note the position of the motor label before
removing the motor! The motor must be mounted
back at the same position!
5. Remove the motor.
3HAC 022032-001 Revision - 181

4 Repair
4.6.2 Refitting of motor, axis 1
A
xx0300000154
A Motor, axis 1
B Connection box with cover
Required
equipment
Motor unit, axis 1 3HAC 5952-1 Includes motor pinion.
(IRB 4400/45, /60, /L10, /L30)
Motor unit, axis 1 3HAC 9841-1 Includes motor pinion.
(IRB 4400/S)
O-ring, motor 2152 0431-11
Gasket 3HAC 4432-1 Between the motor
and the connection
box.
Replace if damaged.
182 Revision - 3HAC 022032-001

4 Repair

defined in section
Standard toolkit in the
Product manual, refer-
ence information.
Power supply 24 VDC, 1.5 A
Used in order to
release the brakes.
Measuring tool 3HAB 7887-1 or Choose one of the
3HAB 1408-1 tools.
below.
Circuit Diagram See chapter Circuit
diagrams in the Prod-
information.
manual, reference
information.
Refitting, motor The procedure below details how to refit the motor, axis 1.
axis 1
Warning!
result in burns!
Note!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!

1. Check that the assembly surfaces are clean from
paint, lubricant etc.
Make sure that the motor and the gearbox are not
damaged or scratched.
2. Fit the o-ring to the new motor unit. Part no. is specified in Required
3HAC 022032-001 Revision - 183

4 Repair

3. Release the brake of the motor by connecting the Connect to connector R3.MP1
24 VDC power supply. • +24V: pin 7
• 0V: pin 8.
4. Apply flange sealing to the motor flange. Art. no. is specified in Required
5. Place the new motor in the gearbox.
Do not damage the pinion and the gear wheel!
Note the position of the motor! The motor label
should be mounted in the same position as it had
before the removal.
6. Fit the upper and lower screws (A, B) and tighten
until there is no space between the motor flange
and the gearbox.
There should be a big backlash between the
motor pinion and the gear.
C
xx0300000155
• A: Lower screw
• B: Upper screw
• C: Pushing direction
7. Adjustment detailed in section
Adjustment of motors, axes 1-3
on page 196.
Note!
Adjust the motor before continuing the refitting

procedure!
8. Fit the other two attachment screws and wash- Total 4 pcs, M10x30. Tightening
ers. torque: 60 Nm.
9. Check the oil level. Fill with oil if necessary. Detailed in section Inspection of
oil levels on page 80.
10. Refit the connection box. Part no. is specified in Required
Replace the gaskets if they are damaged. equipment on page 182.
11. Reconnect all the connectors.
12. Refit the cover of the connection box.
184 Revision - 3HAC 022032-001

4 Repair

detailed in the Calibration Pendu-
lum Instruction, enclosed with
Danger!
it is vital that:
3HAC 022032-001 Revision - 185

4 Repair
xx0300000159
A Motor, axis 2
B Connection box
Required
equipment
section Standard toolkit in the
information.
See references to required.
these procedures in the
step-by-step instruc-
tions below.
Circuit Diagram See the chapter Circuit dia-
grams in the Product manual,
reference information
186 Revision - 3HAC 022032-001

4 Repair
axis 2
Warning!
result in burns!
Note!
used!

1.
Danger!
Secure the arm system before removing the motor!

The brake is located in the motor and is therefore
released when the motor is removed.
2. Remove the cover of the connection box.
4. Remove the connection box. Shown in the figure Location
of motor on page 186.
5. Note the position of the motor label before remov-
ing it. The motor must be mounted in the same
position.
6. Remove the attachment screws and washers of Shown in the figure Location
the motor. of motor on page 186.
Note! Oil will start to run out when removing the
motor!
3HAC 022032-001 Revision - 187

4 Repair
xx0300000159
A Motor, axis 2
B Connection box
Required
equipment
Motor unit, axis 2 3HAC 5954-1 Includes pinion.
O-ring 2152 0431-11
ence information.
Used in order to release the
brakes.
Measuring tool 3HAB 7887-1 Choose one of the two tools.
3HAB 1408-1
188 Revision - 3HAC 022032-001

4 Repair

below.
gram in the Product manual,
reference information
Calibration Pendulum Art. no. is specified in section
Instruction Document references in the
information.
axis 2
Warning!
result in burns!
Note!
used!

2. Mount the o-ring to the new motor unit. Part no. is specified in Required
3. Release the brake of the motor by connecting the Connect to connector R3.MP2
24 VDC power supply. • +24V: pin 7
• 0V: pin 8.
4. Apply flange sealing to the motor flange. Art. no. is specified in Required
Do not damage the pinion or the gear wheel!
Note the position of the motor! The motor label
should be mounted in the same position as it had
before the removal.
3HAC 022032-001 Revision - 189

4 Repair

6. Fit the upper and lower screws (A, B) and tighten
until there is no space between the motor flange
and the gearbox.
There should be a big backlash between the
motor pinion and the gear.
A
B
C
xx0300000160
• A: Upper screw
• B: Lower screw
7. Adjustment is detailed in section
Adjustment of motors, axes 1-3
on page 196.
Note!
Adjust the motor before continuing the refitting

procedure!
8. Fit the other two attachment screws and wash- Shown in the figure Location of
ers. motor on page 188.
2 pcs: M10x70, 2 pcs: M10x30.
9. Refill with oil. Detailed in section Oil in gear-
box unit, axis 1-2-3 on page 79.
10. Refit the connection box. Shown in the figure Location of
motor on page 188.
11. Reconnect the connectors.
13. Recalibrate the robot! Calibration with the Pendulum is
dulum Instruction, enclosed
with the calibration toolkit.
Danger!
it is vital that:
190 Revision - 3HAC 022032-001

4 Repair
xx0300000163
A Motor, axis 3
B Connection box
C Attachment screws and washers, motor
Required
equipment
reference information!
tions below.
Circuit Diagram See the chapter Circuit
diagrams in the Product
mation.
3HAC 022032-001 Revision - 191

4 Repair
axis 3
Warning!
result in burns!
Note!
used!

1.
Danger!
Secure the upper arm system before removing

the motor from axis 3! The brake is located in the
motor and is therefore released when the motor
is removed.
2. Remove the cover from the connection box.
4. Remove the connection box from the motor. Shown in the figure
Location of motor on
page 191.
5. Note the position of the motor label before
removing it! The motor must be mounted in the
same position.
6. Remove the attachment screws and washers, Shown in the figure
motor. Location of motor on
Note! Oil will start to run out when removing the page 191.
motor!
192 Revision - 3HAC 022032-001

4 Repair
xx0300000163
A Motor, axis 3
B Connection box
C Attachment screws and washers, motor
Required
equipment
O-ring 3HAC 2152 0431-11
reference information!
To be used for releasing
the brakes.
Measuring tool 3HAB 7887-1 or Choose one of the two
3HAB 1408-1 tools.
3HAC 022032-001 Revision - 193

4 Repair

See references to required.
these procedures in the
step-by-step instruc-
tions below.
Circuit Diagram See the chapter Circuit
diagrams in the Product
mation.
axis 3
Warning!
result in burns!
Note!
used!

1. Check that the assembly surfaces are
clean from paint, lubricant etc.
Make sure that the motor and the gearbox
are not damaged or scratched.
2. Fit the o-ring to the new motor unit. Part no. is specified in Required equip-
ment on page 193.
3. Release the brake of the motor by con- Connect to connector R3.MP3
necting the 24 VDC power supply. • +24V: pin 7
• 0V: pin 8.
4. Apply flange sealing to the motor flange. Art. no. is specified in Required equip-
ment on page 193.
Do not damage the pinion and the gear
wheel!
Note the position of the motor! The motor
label should be mounted in the same posi-
tion as it had before the removal.
194 Revision - 3HAC 022032-001

4 Repair

6. Fit the upper and lower screws (A, B) and
tighten until there is no space between the
motor flange and the gearbox.
There should be a big backlash between
the motor pinion and the gear. A
B
C
xx0300000160
Motor, axis 2, is shown in the figure!

• A: Upper screw
• B: Lower screw
7. Adjustment is detailed in section
Adjustment of motors, axes 1-3 on
page 196.
Note!
Adjust the motor before continuing the

refitting procedure!
8. Fit the other two attachment screws and Shown in the figure Location of motor
washers, motor. on page 193.
M10x70, M10x30. Tightening torque:
60 Nm.
9. Refill with oil. Detailed in the Maintenance Manual .
10. Refit the connection box. Shown in the figure Location of motor
on page 193.
11. Reconnect the connectors.
13. Recalibrate the robot! Calibration with the Pendulum is
detailed in the Calibration Pendulum
Instruction, enclosed with the calibra-
tion toolkit.
Danger!
it is vital that:
3HAC 022032-001 Revision - 195

4 Repair
4.6.7 Adjustment of motors, axes 1-3
General This section details how to adjust the motors during refitting. It applies to the motors in axes
1, 2 and 3 and is a complement to the refitting instructions found in sections
• Refitting of motor, axis 3 on page 193.
Required
equipment
Product manual.
Measuring tool 3HAB 7887-1 or Choose one of the tools. They
3HAB 1408-1 or are all compatible with the
motor.
For releasing the brakes.
Other tools and pro- These procedures include ref-
cedures may be erences to the tools required.
required. See refer-
ences to these proce-
dures in the step-by-
step instructions
below.
Circuit Diagram See chapter Circuit diagrams
in the Product manual.
Adjustment The procedure below details how to adjust the motors during refitting.

1. Lock the motor brake before mounting
the adjustment tool.
2. Fit the measuring tool to the motor Art. no. is specified in Required equipment
axis. on page 196.
3. Release the brake of the current motor Axis 1 motor: connect to connector R3.MP1
by connecting the 24VDC supply. • +24V: pin 7
• 0V: pin 8.
Axis 2 motor: connect to connector R3.MP2
• +24V: pin 7
• 0V: pin 8.
Axis 3 motor: connect to connector R3.MP3
• +24V: pin 7
• 0V: pin 8.
196 Revision - 3HAC 022032-001

4 Repair

4. Rotate the motor shaft with the mea-
suring tool. Measure the torque in both
directions with a spring balance.
A normal torque is 0.6-0.8 Nm (=6-8 N
on radius 100 mm). Torques higher
than 0.8 Nm are not allowed, as they
will reduce the lifetime of the motor
and gear.
5. Loosen the lower and upper screws
until the motor can be moved side-
ways by hand.
Note! The brake must be released in
the motor.
6. Push the motor with one hand against
the gear and tighten the two screws
with the other hand.
1)
7. Measure the torque with the motor The brake disc is mounted on the motor
shaft in different positions. The torque shaft with a type of splined coupling.
should be max. 0.1 Nm (on radius 50 Between the splines there is a narrow back-
mm) more than measured before. lash.
If the torque is more, Note! There should always be a backlash,
• slightly loosen the screws a lit- but it should be as minimal as possible.
tle and carefully knock the
motor in the opposite direction
• then measure the torque
again.
Check that the backlash is very lim-
ited, by moving the tool back and for-
ward in small movements.
When turning the motor shaft, a tick-
tack sound can be heard from the
brake disc 1) . This should not be
mixed up with the backlash. The diffi-
cult part is to find the motor position
where the torque just starts to
increase.
8. Remove the measuring tool.
9. Disconnect the brake release voltage.
10. Continue refitting the motor. Refitting, motor axis 1 on page 183
Refitting, motor axis 2 on page 189
Refitting, motor axis 3 on page 194
3HAC 022032-001 Revision - 197

4 Repair
4.6.8 Removal of motor, axes 4, 5 and 6
Location of The motors, axes 4, 5 and 6, are located as shown in the figure below.
motors The motor and the drive gear of each axis constitute one unit.
D A
x
B
E
C
x-x
xx0300000164
A Motor unit, axis 4

B Motor unit, axis 5
C Motor unit, axis 6
D Attachment screws and washers, motor
E Connection box
Required
equipment
refernce information.
198 Revision - 3HAC 022032-001

4 Repair

Circuit Diagram Art. no. is specified in sec-
Removal, motor The procedure below details how to remove the motors of axes 4, 5 and 6.
axes 4, 5 and 6
Warning!
result in burns!
Note!
used!

1.
Danger!
Secure the arm system before

removing any motor! The brake is
located in the motor and is therefore
released when the motor is removed!
2. Drain the oil from the gearbox. Draining is detailed in section:
Oil change, gearbox axis 4 on page 84
Oil change, gearbox axis 5 and 6 (all robot
versions except IRB 4400/L10) on page 86
Oil change, gearbox axis 5 and 6 (IRB 4400/
L10 only) on page 89.
3. Remove the cover of the connection
box.
4. Disconnect all the connectors in the
connection box.
5. Remove the connection box. Shown in the figure Location of motors on
page 198.
6. Note the position of the motor before
removing it. The motor must be
mounted back at the same position.
7. Remove the attachment screws and Shown in the figure Location of motors on
washers, motor. page 198.
3HAC 022032-001 Revision - 199

4 Repair
Location of motor The motors, axes 4, 5 and 6, are located as shown in the figure below.
The motor and the drive gear of each axis constitute one unit.
A more detailed view of the component and its position may be found in the Foldout section,
D A
x
B
E
C
x-x
xx0300000164

E Connection box
Required
equipment
O-ring 2152 2012-426
Between the motors and the
connection box.
Replace if damaged.
the Product manual,
200 Revision - 3HAC 022032-001

4 Repair

Measuring tool 3HAB 1409-1
Power supply 24VDC, 1.5A
Used to release the brake of
the motor.
below.
ual, refernce information.
axis 4
Warning!
result in burns!
Note!
used!

clean from paint, lubricant etc.
Make sure that the motor and the gear-
box are not damaged or scratched.
2. Fit the o-ring to the new motor unit. Part no. is specified in Required equip-
ment on page 200.
3. Fit the measuring tool to the rear of the Art. no. is specified in Required equip-
motor. ment on page 200.
4. Release the brake of the motor by con- Connect to connector R3.MP4
necting the 24 VDC power supply. • +24V: pin 7
• 0V: pin 8.
5. Place the new motor unit in the gearbox.
Do not damage the pinion or the gear
wheel.
3HAC 022032-001 Revision - 201

4 Repair

6. Find the position with the least play by
turning the motor shaft 10 turns, noting
changes in play as you turn the motor.
7. Push the motor in a radial direction so
that the play is minimal within one motor
turn without the gear "chewing".
8. Refit the motor with its attachment Shown in the figure Location of motor on
screws and washers, motor. page 200.
4 pcs, M6x25. Tightening torque: 15 Nm.
9. Refill with oil, if drained. Detailed in section Oil change, gearbox
axis 4 on page 84.
10. Check the position of the three gaskets, Part no. is specified in Required equip-
located between the motors and the con- ment on page 200.
11. Refit the connection box. Shown in the figure Location of motor on
Make sure the gaskets are seated prop- page 200.
erly!
13. Refit the cover to the connection box.
in Pendulum Calibration Instruction,
Danger!
it is vital that:
202 Revision - 3HAC 022032-001

4 Repair
D A
x
B
E
C
x-x
xx0300000164

E Connection box
Required
equipment
(IRB 4400/45, /60, /L30,
/S)
(IRB 4400/L10)
O-ring 2152 2012-426
Between the motor and the
connection box.
Replace if damaged.
3HAC 022032-001 Revision - 203

4 Repair

Product manual, refernce
information.
2 pcs, used to release the
brakes in the motors for axes
4 and 5.
below.
Circuit Diagram See chapter Circuit diagrams
Product manual, refernce
information.
Refitting, motor The procedure below details how to refit the axis 5 motor.
axis 5
Warning!
result in burns!
Note!
used!

2. Fit the o-ring into the new motor. Part no. is specified in Required
3. Fit the measuring tool to the rear of the motor. Art. no. is specified in Required
204 Revision - 3HAC 022032-001

4 Repair

4. Release the brakes in the motors for axes 4 and Connect to connector R3.MP4/
5, by connecting the 24 VDC power supply. MP5
• +24V: pin 7
• 0V: pin 8.
Do not damage the pinion or the gear wheel.
6. Find the position of least play by turning the out-
going shaft for axis 4 in intervals of 90°, one turn
in all, to locate the area where the play for the
motor axis 5 is the smallest.
7. Turn the motor for axis 5 one full turn at a time,
five turns in all. Find the smallest play within this
range.
8. Push the motor in a radial direction so that the
play is minimal within one motor turn without the
gear "chewing".
9. Refit the motor with its attachment screws and Shown in the figure Location of
washers, motor. motor on page 203.
4 pcs, M6x25. Tightening
torque: 15 Nm.
10. Refill with oil, if drained. Detailed in sections
(all robot versions except IRB
4400/L10) on page 86
(IRB 4400/L10 only) on page 89.
11. Check the position of the three gaskets , located Part no. is specified in Required
between the motors and the connection box. equipment on page 203.
Replace them if damaged.
12. Refit the connection box. Shown in the figure Location of
Make sure the gaskets are seated properly! motor on page 203.
14. Refit the cover on the connection box.
dulum Instruction, enclosed with
the section Calibration on page
219.
Danger!
it is vital that:
3HAC 022032-001 Revision - 205

4 Repair
D A
x
B
E
C
x-x
xx0300000164

E Connection box
Required
equipment
(IRB 4400/45, /60, /L30, /S)
(IRB 4400/L10)
O-ring 2152 2012-426
Between the motors and
the connection box.
Replace if damaged.
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4 Repair

3 pcs, used to release the
brakes in the motors for
axes 4, 5 and 6.
tions below.
Circuit Diagram Art. no. is specified in
section Document refer-
mation.
Calibration Pendulum Art. no. is specified in
Instruction section Document refer-
manual, refernce infor-
mation.
Refitting, motor The procedure below details how to refit the axis 6 motor.
axis 6
Warning!
result in burns!
Note!
used!

clean from paint, lubricate etc.
Make sure that the motor and the gearbox
are not damaged or scratched.
2. Fit the o-ring to the new motor unit . Part no. is specified in Required equip-
ment on page 206.
3. Fit the measuring tool at the rear of the Art. no. is specified in Required equip-
motor. ment on page 206.
3HAC 022032-001 Revision - 207

4 Repair

4. Release the brakes in the motors for axes Connect to connector R3.MP4/MP5/MP6
4, 5 and 6, by connecting the 24 VDC • +24V: pin 7
power supply.
• 0V: pin 8.
Do not damage the pinion or the gear
wheel!
6. Find the position of least play by turning the
outgoing shaft for axis 4 in intervals of 90°,
one turn in all, to locate the area where the
play for the axis 6 motor is the smallest.
7. Turn the motor for axis 5 one full turn at a
time, five turns in all. Find the least play for
axis 6 within this range.
8. Turn the motor for axis 6 one full turn at a
time, three turns in all. Find the least play
for axis 6 within this range.
9. Push the motor in a radial direction so that
the play is minimal within one motor turn
without the gear "chewing".
10. Refit the motor with its attachment screws Shown in the figure Location of motor on
and washers, motor. page 206.
4 pcs, M6 x 25. Tightening torque: 15
Nm.
11. Refill with oil, if drained. Detailed in sections
Oil change, gearbox axis 5 and 6 (all
robot versions except IRB 4400/L10) on
page 86
Oil change, gearbox axis 5 and 6 (IRB
4400/L10 only) on page 89.
12. Check the position of the three gaskets , Part no. is specified in Required equip-
located between the motors and the con- ment on page 206.
13. Refit the connection box . Shown in the figure Location of motor on
Make sure the gaskets are seated properly! page 206.
15. Refit the cover on the connection box.
in Calibration Pendulum Instruction ,
Danger!
it is vital that:
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4 Repair
4.7.1 Removal of gearbox unit, axes 1-2-3
4.7: Gearboxes
General The gearboxes of axes 1-2-3 are handled as one complete unit. Except for the gearboxes, the
spare part also includes motor units and lubricating oil for the axes 1, 2 and 3.
Location of The gearbox unit, axes 1-2-3, is shown in the figure below.
gearbox unit A more detailed view of the component and its position may be found in the Foldout section!
C B
xx0300000174
A Gearbox unit axes 1-3, spare part

B Bottom plate
C Attachment screws and washers, gearbox unit
D Sealing
3HAC 022032-001 Revision - 209

4 Repair
Required
equipment
information!
Lifting slings with hoisting Lifting capacity: 500 kg.
block
below.
Removal, The procedure below details how to remove the gearbox unit, axis 1-2-3, including the
gearbox unit motors, from the manipulator.
Warning!
result in burns!
Caution!
The gearbox unit weighs 360 kg! All lifting equipment used must be dimensioned accord-
ingly!
Caution!
The base weighs 130 kg! All lifting equipment used must be dimensioned accordingly!

1. Remove the cable harness and serial Detailed in sections Removal of cable
measuring board. harness, axes 1-3 on page 98, Removal
of cable harness, axes 4-6 on page
105and Replacement of serial measure-
ment unit on page 173.
2. Remove the tie rod. Detailed in section Removal of tie rod on
page 153.
3. Remove the parallel arm. Detailed in section Removal of parallel
arm /Removal of bearing on page 158.
4. Remove the complete arm system. Detailed in section Removal of complete
arm system on page 114.
5. Unfasten the manipulator from the foun-
dation.
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4 Repair

6. Fit and secure straps (A) around the rear
B
part of the gearbox unit, as shown in the
figure to the right. Attach the straps to
lifting slings with a hoisting block.
Fit and secure hooks to the lifting lugs A
(B).
Use the same crane for both attachment
points.
xx0300000172
7. Lift the gearbox unit together with the

base and use the hoisting block to tip the
complete assembly forward 90°.
8. Place the assembly on a level surface
and support it at position A, according to
the figure on the right.
Make sure the unit is stable and rests
securily before removing the lifting
equipment.
xx0300000173
• B: Approximately 200 mm
9. Remove the bottom plate from the Shown in the figure Location of gearbox
base. unit on page 209.
10. Move the lifting straps to the base and
unload its weight.
11. Remove the attachment screws and Shown in the figure Location of gearbox
washers, gearbox unit. unit on page 209.
12. Remove the base from the gearbox unit.
13. Remove the sealing from the gearbox
unit.
3HAC 022032-001 Revision - 211

4 Repair
4.7.2 Refitting of gearbox unit, axes 1-2-3
General The gearboxes of axes 1-2-3 are handled as one complete unit. Except for the gearboxes, the
spare part also includes motor units and lubricating oil for the axes 1, 2 and 3.
Location of The gearbox unit, axes 1-2-3, is shown in the figure below.
gearbox unit A more detailed view of the component and its position may be found in the Foldout section!
C B
xx0300000174
A Gearbox unit axes 1-3, spare part

B Bottom plate
C Attachment screws and washers, gearbox unit
D Sealing
212 Revision - 3HAC 022032-001

4 Repair
Required
equipment
Gearbox unit, axes 1-3 3HAC 5948-1 Includes motors and lubricat-
(IRB 4400/45, /60, /L10, ing oil.
/L30)
Gearbox unit, axes 1-3 3HAC 5949-1 Includes motors and lubricat-
(IRB 4400/S) ing oil.
Gearbox unit axes, 1-3 3HAC 3502-1 Does not include motors or
lubricating oil.
Sealing 3HAC 5479-2 Replace if damaged.
ence information!
Lifting slings with hoist- Lifting capacity: 500 kg.
ing block
below.
information.
Refitting, gearbox The procedure below details how to refit the gearbox unit, including motors, to the manipu-
unit lator.
Warning!
result in burns!
Caution!
The gearbox unit weighs 360 kg! All lifting equipment used must be dimensioned accord-
ingly!
Caution!
The base weighs 130 kg! All lifting equipment used must be dimensioned accordingly!
3HAC 022032-001 Revision - 213

4 Repair

1. Place the new gearbox unit on a level Part no. is specified in Required equip-
surface and support it at position A, ment on page 213.
according to the figure on the right.
Make sure the unit is stable and rests
securily on the surface, including the
weight of the base that is to be refitted.
xx0300000173
• B: Approximately 200 mm
2. Refit the sealing to the gearbox unit. Shown in the figure Location of gearbox
Replace it if damaged. unit on page 212.
Part no. is specified in Required equip-
ment on page 213.
3. Raise the base and fit it to the gearbox
unit.
Align the hole pattern of the base to the
gearboxes. Turn the gear if necessary
by the motor pinion, axis 1.
4. Refit the base with the attachment Shown in the figure Location of gearbox
screws and washers, gearbox unit. unit on page 212.
14 pcs, M16x80. 12.9 quality UNBRAKO.
Reused screws may be used, providing
they are lubricated as detailed in Screw
Joints in the Product manual, reference
information before fitting.
5. Refit the bottom plate with its attach- Shown in the figure Location of gearbox
ment screws. unit on page 212.
6. Strap the gearbox unit as in the removal See section Removal, gearbox unit on
instruction. page 210.
7. Lift the gearbox unit together with the
base and use the hoisting block to tip
the complete assembly backward by
90°, into normal mounting position.
8. Refit the manipulator to the foundation.
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4 Repair

9. Refit the complete arm system. Detailed in section Refitting of complete
arm system on page 116.
10. Refit the parallel arm. Detailed in section Refitting of parallel
arm /Refitting of bearing on page 161.
11. Refit the tie rod. Detailed in section Refitting of tie rod on
page 155.
12. Refit the cable harness and serial mea- Detailed in sections Refitting of cable har-
suring board. ness, axes 1-3 on page 101, Refitting of
cable harness, axes 4-6 on page 109and
Replacement of serial measurement unit
on page 173.
13. Recalibrate the robot! Calibration with the Pendulum is detailed
Danger!
it is vital that:
3HAC 022032-001 Revision - 215

4 Repair
4.7.3 Adjusting play on axis 4, intermediate gear
Illustration, In order to adjust the play on axis 4, the gear must be accessible. The figure below shows the
adjusting play parts in the upper arm housing that must be removed/unlocked.
B
C
xx0300000191
A Cover
B Attachment screws, cover
C Screws, 3 pcs
Required
equipment
ence information.
below.
Adjusting play, The procedure below details how to adjust the play for the intermediate gear of axis 4.
axis 4
Warning!
result in burns!
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4 Repair

1. Remove the motors for axes 4, 5 and 6. Detailed in section Removal of motor,
axes 4, 5 and 6 on page 198.
2. Remove the cover . Shown in the figure Illustration, adjust-
ing play on page 216.
3. Unlock the three screws . Shown in the figure Illustration, adjust-
ing play on page 216.
4. Rotate axis 4 to find the highest position of
the gear on the upper arm tubular.
5. Tighten the three screws again. 3 pcs, tightening torque: 69 Nm.
6. Apply flange sealing to the cover and refit Art. no. is specified in Required equip-
it with its attachment screws and washers ment on page 216.
. 10 pcs: M8x40. Tightening torque: 24
Nm.
3HAC 022032-001 Revision - 217

4 Repair
218 Revision - 3HAC 022032-001

5 Calibration
5.0.1 Introduction
5: Calibration
5.0.1 Introduction
Calibration This chapter details how to calibrate the robot with the Wyler calibration equipment, using
methods Levelmeter 2000.
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 Calibrate the measurement system carefully as detailed in section Calibration on page 230 if
values any of the resolver values have changed. This may occur when parts affecting the calibration
position are replaced on the robot.
Contents of the Calibrate the system roughly as detailed in section Updating the revolution counters on page
revolution 248 if the contents of the revolution counter memory are lost. This may occur when:
counter memory • the battery is discharged
are lost
• a resolver error occurs
• the signal between a resolver and measurement board is interrupted
• a robot axis is moved with the control system disconnected
3HAC 022032-001 Revision - 219

5 Calibration
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 The calibration procedure with Wyler equipment may be performed with either one or two
Calibration 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, cali-
bration
Step Action Note
1. Check that all required hardware is Required hardware is specified in the cali-
available for calibrating the robot. brating procedures for each axis.
2. Manually run the robot axes to a posi- Use the calibration scales fitted to each
tion close to the correct calibration robot axis to locate this position. These are
position. shown in the section Calibration scales and
correct axis position on page 222.
3. Initialize the Levelmeter. Detailed in section Initialization of Levelme-
ter 2000 on page 228.
4. Start the calibration procedure on the Detailed in section Fine calibration proce-
TPU. dure on TPU on page 230.
5. Calibrate each axis. Detailed in each axis’ calibration instruction.
6. Verify that the calibration was suc- Detailed in section Post calibration proce-
cessfully carried out. dure on page 250.
Additional infor- In addition to the basic calibration procedure detailed above, a number of calibration related
mation actions may be performed:
Action Detailed in section:

How to update the robot revolution counter without perform- Updating the revolution
ing a complete calibration. counters on page 248
How to manually check the current calibration position. Checking the calibration posi-
tion on page 225
220 Revision - 3HAC 022032-001

5 Calibration
5.1.2 Calibration, prerequisites
5.1.2 Calibration, prerequisites
Peripheral The robot must be free from any peripheral equipment during calibration. Fitted tools and
equipment 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 The positions where the calibration sensor and reference sensor should be fitted during cali-
sensors bration, are specified in Positions and directions of sensor on page 226.
3HAC 022032-001 Revision - 221

5 Calibration
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 infor- Read the safety information below.

mation
Warning!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
- The operating mode selector on the controller must be in the manual mode position to render
the enabling device operative and to block operation from a computer link or remote control
panel.
- The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in posi-
tion < 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 28.
222 Revision - 3HAC 022032-001

5 Calibration
Calibration scales The calibration marks for axes 2, 3, 4 and 5 are marked using punch mark tools.
The illustration below shows the calibration scale positions:
E
xx0300000209
A Punch, axis 2, 3HAB 1521-1

B Punch, axis 3, 3HAB 1522-1
C Punch, axis 4, 3HAB 1523-1 (there are two different versions of the marks,
according to the figure)
D Punch, axis 5, 3HAB 1524-1
E Axes 5 and 6, IRB 4400/L10
3HAC 022032-001 Revision - 223

5 Calibration
5.2.2 Directions for all axes
5.2.2 Directions for all axes
Calibration When calibrating, the axis must consistently be run towards the calibration position in the
movement direc- same direction, in order to avoid position errors caused by backlash in gears etc. Positive
tions 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!
6+ 4+
5+
3+
2+
1+
xx0200000089
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5 Calibration
5.2.3 Checking the calibration position
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 Step Action Button
system software 1. Run the program \SYSTEM\UTIL-
ITY\SERVICE\CALIBRAT\CALxxxx in the
system and follow the instructions dis-
played on the teach pendant.
2. Switch to MOTORS OFF when the robot Calibration marks are shown in section
stops. Check that the calibration marks for Calibration scales and correct axis
that particular axis align correctly. If they position on page 222.
do not, update the revolution counters. Detailed in section Updating the revo-
lution counters on page 248.
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).
Using the
Jogging window
on the teach Step Action Illustration
pendant 1. Open the Jogging window.
xx0100000195
2. Choose running axis-by-axis.
xx0100000196
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 particu- Shown in section Calibration
lar axis align correctly. If they do not, update the scales and correct axis position
revolution counters ! on page 222.
Detailed in section Updating the
revolution counters on page 248.
3HAC 022032-001 Revision - 225

5 Calibration
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 Reset-
ting of Levelmeter 2000 and sensor on page 233. 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 dif-
ferent 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 The sensor is positioned and aligned on the axes as shown in the figure below.
reference sensor
position, IRB
4400
B1
C H
G I
xx0300000204
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5 Calibration
A Flange plate
B Axis 2 sensor
B1 Axis 2 sensor, view from above
C Axis 3 sensor
D Axis 4 sensor
E Axis 5 sensor
F Axis 6 sensor
G Upper arm, view from above
H Direction for sensor at reference plane, axis 2, 3 and 5
I Direction for sensor at reference plane, axis 4 and 6
3HAC 022032-001 Revision - 227

5 Calibration
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 228.
2. Set the measuring unit, as detailed in Measuring units on page 229.
3. Install sensor, as detailed in Installation of sensor on page 229.
4. Calibrate the robot, as detailed in the instruction for each axis respectively, in the sec-
tion Calibration on page 219!
Levelmeter 2000 The Levelmeter 2000 is shown for reference below:
- 0000000
00000
+
Port/Sensor
A
° oo
GON
A°oo mRAD mm/m DEG
"1/12" "1/10" "/REL" mm/REL A
50
BATT B
LEVELMETER 2000
+
ON/MODE
ZERO SELECT
-
ENTER
C HOLD SEND/ESC
WYLER
A B OUT
xx0200000083
A Measuring unit
B Selection pointer
C Sensor connection
Select filter type

1. Press ON/MODE until the dot flashes under FIL- Shown in the figure Levelmeter
TER . 2000 on page 228!
2. Press ENTER.
3. The standard filter type no. 5 flashes. Default setting is filter type 5.
228 Revision - 3HAC 022032-001

5 Calibration

4. If type 5 does not flash, press ZERO/SELECT to
select filter type 5 and press ENTER .
Measuring units

1. Press ON/MODE until the dot flashes under Shown in the figure Levelmeter
UNIT . 2000 on page 228!
2. Press ENTER.
3. Press ZERO/SELECT until mm/m flashes.
Two decimals (0.00) are shown on the display
4. Press ENTER.
Installation of
sensor
1. Connect the sensor to the Sensor connection Shown in the figure Levelmeter
point. 2000 on page 228!
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.
Result The Levelmeter 2000 is now initialized and ready for service.
3HAC 022032-001 Revision - 229

5 Calibration
5.3.1 Fine calibration procedure on TPU
5.3: Calibration
General This section details how to use the Teach Pendant Unit (TPU) when performing a fine cali-
bration of the robot. The method of fitting the calibration equipment to each axis is detailed
in the calibration instruction for the axis.
Procedure

1. Press the button "Mis-
cellaneous".
xx0100000194
2. Select the Service

window by pressing
ENTER.
xx0100000200
3. Select Calibra-
tion from the View
menu. The Calibration
window appears.
If multiple units are
connected to the
robot, they will be
listed in the window.
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
248.
• Not calibrated: one (or more) of the axes is NOT
fine-calibrated. This axis, or these axes, must
therefore be fine-calibrated as detailed in the cali-
bration instructions for each axis.
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5 Calibration

4. Select the desired unit
and choose Fine
Calibrate from the
Calib menu. A
Warning window
appears.
xx0100000203
5. Move the manipulator Calibration positions for the manipulator are detailed in
to its calibration posi- section Checking the calibration position on page 225.
tion and press OK.
The Fine Calibrate
window appears.
xx0100000204
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 win-
dow.
3HAC 022032-001 Revision - 231

5 Calibration

8. Press OK again to
confirm and start the
update.
CANCEL returns to
the Fine Calibration
window.
An alert box is dis-
played during calibra-
tion. The Status
window appears when
the fine calibration is
complete. The revolu-
tion counters are
always updated at the
same time as the cali-
bration is performed.
232 Revision - 3HAC 022032-001

5 Calibration
5.3.2 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:
- 0000000
00000
+
Port/Sensor
A
° oo
GON
A°oo mRAD mm/m DEG
"1/12" "1/10" "/REL" mm/REL A
50
BATT B
LEVELMETER 2000
+
ON/MODE
ZERO SELECT
-
ENTER
C HOLD SEND/ESC
WYLER
A B OUT
xx0200000083
A Measuring unit
B Selection pointer
C Sensor connection
Sensor mounted When using the sensor as a reference sensor it is fitted to the sensor fixture, together with a
on fixture sensor plate, as shown below.
See the section Positions and directions of sensor on page 226 for actual positioning and
orientation of the fixture and the sensor, since the direction of the sensor differs depending on
which axis is calibrated.
A
X
B C
xx0100000207
3HAC 022032-001 Revision - 233

5 Calibration
A Reference sensor, fitted to the sensor plate (actual direction differs)

B Sensor fixture, fitted on manipulator base
C Attachment screws, sensor plate
Required
equipment
Levelmeter, one sensor 6369 901-347 Includes one sensor.
Sensor plate 3HAC 0392-1
Sensor fixture 6808 0011-GM
Isopropanol 1177 1012-108 For cleaning the sensor fixture.
Note!
Always secure the sensor to the sensor fixture using screws and with approximately the same
torque each time!
Note!
Always fit the sensor in the same direction when resetting it as when performing the calibra-
tion for each axis!
Note!
Always reset the sensor when using it in a new direction!
Resetting

1. If the sensor and the sensor plate are separate, Art. no. is specified in Required
fit them together by first cleaning the attach- equipment on page 234.
ment 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 accord-
ing to section Initialization of Levelmeter 2000
on page 228.
3. Remove the cover plate on the reference sur- Shown in the section Positions
face on the manipulator base. and directions of sensor on page
226.
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. equipment on page 234!
Orientation is specified in section
Positions and directions of sensor
on page 226!
234 Revision - 3HAC 022032-001

5 Calibration

6. Clean the sensor plate attachment area on the
fixture with isopropanol.
7. Fit the sensor unit (sensor plate and sensor) on Correct direction is shown in Posi-
to the sensor fixture and connect the sensor to tions and directions of sensor on
the Levelmeter 2000. page 226.
Connection is shown in the figure
Levelmeter 2000 on page 233.
8. Press ON/MODE on the Levelmeter 2000 until Shown in the figure Levelmeter
the dot flashes under REL ZERO . 2000 on page 233!
9. Press ENTER.
10. Wait until + or - flashes.
11. Press HOLD .
12. Wait until + or - flashes.
13. Press ENTER.
Result 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.
3HAC 022032-001 Revision - 235

5 Calibration
5.3.3 Calibration, axis 1, IRB 4400
Calibration of The special calibration equipment is fitted to the base of the manipulator as shown in the
axis 1 figure below.
A
xx0300000202
A Guide pin in gearbox

B Calibration tool, axis 1
C Measuring pin, axis 1
Required
equipment
Isopropanol 1177 1012-208 Used to clean the reference
surface.
Calibration tool, axis 1 3HAB 1526-1
Measuring pin, axis 1 6808 0011-GR
Guide bars 2 pcs
Used to align the measure-
ment pin.
Calibration, axis 1 The procedure below details how to perform the actual calibration of axis 1 using the calibra-
tion equipment specified in Required equipment.
Caution!
If the manipulator normally works in an inverted position, it must be removed from this posi-
tion and placed on the floor before the work detailed in this instruction may be carried out !
236 Revision - 3HAC 022032-001

5 Calibration

1. Move the robot to its calibration position cor- See section Calibration scales and
responding to the calibration scales. correct axis position on page 222.
2. Remove the cover plate on the reference sur- Art. no. is specified in Required
face on the base of the manipulator. equipment on page 236.
Clean the surface with isopropanol and
deburr it.
3. Fit the calibration tool, axis 1 on the guide pin Art. no. is specified in Required
underneath the gearbox. equipment on page 236.
Shown in the figure Calibration of
axis 1 on page 236.
4. Fit the measuring pin to the calibration tool. Art. no. is specified in Required
Shown in the figure Calibration of
axis 1 on page 236.
5. Release the brakes and move the manipula-
tor manually so that the measuring pin can be
placed in the guide hole on the base.
6. Put two guide bars on the tool and align the
C
pin, as shown in the figure to the right.
A
B
xx0300000203
• A: Calibration tool, axis 1

• B: Measuring pin, axis 1
• C: Guide bars
7. Update only axis 1, using the TPU. Detailed in section Fine calibration
procedure on TPU on page 230.
8. Remove the calibration tool for axis 1.
9. Refit the cover plate to the reference surface
on the base of the manipulator, if no other cal-
ibration is to be performed.
3HAC 022032-001 Revision - 237

5 Calibration
5.3.4 Calibration, axis 2
General This section details how to perform the actual fine calibration of axis 2 using the Wyler cali-
bration equipment.
Required
equipment
Levelmeter 2000 calibration kit with one 6369 901-347 Includes one sensor.
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 These procedures include
required. See references to these proce- references to the tools
dures in the step-by-step instructions below. 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 Action Illustration

1. Reset the levelmeter and the sensor for cal- Detailed in section Resetting of Lev-
ibration of axis 2. elmeter 2000 and sensor on page
233.
2. Clean the calibration surface with isopro- Art. no. is specified in Required
panol. equipment on page 238!
3. Fit the angle bracket on the lower arm. Art. no. is specified in Required
Adjust the angle of the bracket to make it equipment on page 238!
level.
4. Fit the calibration sensor together with the Shown in section Positions and direc-
sensor plate on the angle bracket on axis 2. tions of sensor on page 226!
Carefully tighten the securing screws with
approximately same tightening torque that
used at the reference plane!
238 Revision - 3HAC 022032-001

5 Calibration

5. Manually run axis 2 in with the joystick to Correct measurement on the level-
the correct position as indicated by the lev- meter:
elmeter. 0 ±0.40 mm/m
Tip!
Reduce the jogging velocity in order to eas-

ily position the axis as close to zero as pos-
sible!
6. Update only axis 2. Detailed in section Fine calibration
7. Remove the sensor.
8. Refit the cover plate on the calibration sur-
face on the manipulator lower arm. Refit
also the cover plate on the reference sur-
face at the base if no further calibration is
performed.
9. Check the calibration according to section
Post calibration procedure on page 250 or
continue with calibration of next axis.
3HAC 022032-001 Revision - 239

5 Calibration
bration equipment.
Required
equipment
Equipment Art. no. Info
Sync adapter 3HAB 1525-1 Adapter to be fitted on the turning disk.
Includes guide pin 2111 2021-399.
Guide pin 2111 2021-399 To be used with Sync adapter.
Levelmeter 2000 calibration kit 6369 901-347 Includes one sensor.
with one sensor
Sensor plate 3HAC 0392-1 One sensor plate is required for each
sensor.
Turning disk fixture 6808 0011-GU For fitting the calibration sensor plate to
the sync adapter.
Isopropanol 1177 1012-108 For cleaning the attachment points.
Other tools and procedures may These procedures include references to
be required. See references to the tools required.
Tip!
Procedure
Step Action Illustration/Info

1. Clean the manipulator turning disk with isopro- Art. no. is specified in Required
panol. equipment on page 240!
2. Fit the sync adapter to the turning disk. Art. no. is specified in Required
Fit the turning disk fixture (incl. guide pin) on equipment on page 240!
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\SER-
VICE\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 Detailed in section Resetting of
the sensor for calibration of axis 3. Levelmeter 2000 and sensor on
page 233.
240 Revision - 3HAC 022032-001

5 Calibration
Step Action Illustration/Info

6. Fit the calibration sensor unit (sensor and Shown in the section Positions
plate) on the turning disk fixture. and directions of sensor on page
Carefully tighten the securing screws with 226!
used at the reference plane.
7. Manually run axis 3 in with the joystick to the Correct measurement on the lev-
correct position as indicated by the levelmeter. elmeter:
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. Detailed in section Fine calibra-
tion procedure on TPU on page
230.
10. Check the calibration according to section Post
calibration procedure on page 250 or continue
with calibration of next axis.
11. Refit the cover plate on the reference surface
on the base if no further calibration is per-
formed.
3HAC 022032-001 Revision - 241

5 Calibration
bration equipment.
Required
equipment


Levelmeter 2000 calibration 6369 901-347 Includes one sensor.
kit with one sensor
Sensor plate 3HAC 0392-1 One sensor plate is required for each sensor.
Turning disk fixture 6808 0011-GU For fitting the calibration sensor plate to the
sync adapter.
Other tools and procedures These procedures include references to the
may be required. See refer- tools required.
ences to these procedures
tions below.
Tip!
Procedure

panol . equipment on page 242!
Fit the turning disk fixture (incl. pin) on the turning equipment on page 242!
disk.
e.g. 7600) in the system and select Calib: CAL4A.
The robot moves to the position for calibration of
axis 4.
page 233.
242 Revision - 3HAC 022032-001

5 Calibration

6. Fit the calibration sensor unit (sensor and plate) Shown in the section Positions
on the turning disk fixture. and directions of sensor on
Carefully tighten the securing screws with page 226!
approximately same tightening torque that used
at the reference plane.
7. Manually run axis 4 in with the joystick to the cor- Correct measurement on the
rect position as indicated by the levelmeter. levelmeter:
0 ±0.80 mm/m
Tip!

230.
10. Select Calib: CAL4B.
The axis 4 moves 90º, to a correct position.
230.
12. Check the calibration according to section Post
calibration procedure on page 250 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.
3HAC 022032-001 Revision - 243

5 Calibration
bration equipment.
Required
equipment
Levelmeter 2000 calibration kit 6369 901-347
with one sensor
sensor.
the sync adapter.
Other tools and procedures may These procedures include references to
be required. See references to the tools required.
Tip!
Procedure

panol . equipment on page 244!
Fit the turning disk fixture (incl. pin) on the equipment on page 244!
turning disk.
e.g. 7600) in the system and select Calib:
CAL5.
The robot will now move to the position for cal-
ibration of axis 5.
page 233.
244 Revision - 3HAC 022032-001

5 Calibration

6. Fit the calibration sensor on the turning disk Shown in the section Positions
fixture. and directions of sensor on page
Carefully tighten the securing screws with 226!
7. Manually run axis 5 in with the joystick to the Correct measurement on the level-
correct position as indicated by the levelmeter. meter:
0 ±0.80 mm/m
Tip!

8. Update only axis 5. Detailed in section Fine calibration
Post calibration procedure on page 250 or
continue with calibration of next axis.
11. Refit the cover plate on the reference surface
at the base if no further calibration is per-
formed.
3HAC 022032-001 Revision - 245

5 Calibration
bration equipment.
Required
equipment
Levelmeter 2000 calibration kit 6369 901-347
with one sensor
sensor.
the sync adapter.
Other tools and procedures These procedures include references to
may be required. See refer- the tools required.
ences to these procedures in
below.
Tip!
Procedure

1. Calibrate axis 5. Detailed in section Calibration, axis 5
on page 244.
2. Reset the levelmeter with correct orienta- Detailed in section Resetting of Level-
tion of the sensor for calibration of axis 6. meter 2000 and sensor on page 233.
3. Fit the calibration sensor unit (sensor and Shown in section Positions and direc-
plate) on the turning disk fixture. tions of sensor on page 226!
Carefully tighten the securing screws with
246 Revision - 3HAC 022032-001

5 Calibration

4. Manually run axis 6 in with the joystick to Correct measurement on the levelme-
the correct position as indicated by the lev- ter:
elmeter. 0 ±0.80 mm/m
Tip!
Reduce the jogging velocity in order to

easily position the axis as close to zero as
possible!
5. Update only axis 6. Detailed in section Fine calibration pro-
cedure on TPU on page 230.
Post calibration procedure on page 250.
8. Refit the cover plate on the reference sur-
face at the base.
3HAC 022032-001 Revision - 247

5 Calibration
5.3.9 Updating the revolution counters
Manually running This section details the first step when updating the revolution counter; manually running the
the manipulator manipulator to the calibration position.
to the calibration
position
1. Select axis-by-axis motion mode.
2. Press the enabling device on the teach pendant Shown in section Calibration
and, using the joystick, move the robot manually scales and correct axis position
so that the calibration marks lie within the toler- on page 222.
ance zone.
Axes 5 and 6 must be positioned together!
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 man-
ually before the robot has been calibrated.
4. When all axes are positioned as above, store the
revolution counter settings using the Teach Pen-
dant Unit as detailed below:
Storing the revo- This section details the second step when updating the revolution counter; storing the revolu-
lution counter tion counter setting.
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!

1. Press the button "Miscel-
laneous".
xx0100000194
2. Select the Service

window by pressing
ENTER.
xx0100000200
248 Revision - 3HAC 022032-001

5 Calibration

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.
xx0100000201
4. Select the desired unit

and choose Rev
Counter Update from
the Calib menu.
The Revolution Counter
Update window appears.
xx0100000202
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 con-
firm and start the update.
CANCEL returns to the
Revolution Counter
Update window.
8. At this point, it is recom- Not required.
mended that the revolu-
tion counter values are
saved to a diskette.
9. Recheck the calibration Detailed in section Checking the calibration position on
position. page 225
3HAC 022032-001 Revision - 249

5 Calibration
5.4.1 Post calibration procedure
5.4: After calibration
5.4.1 Post calibration procedure
General Perform the following procedure after calibrating any manipulator axes. The procedure is
intended to verify that all calibration positions are correct.
Procedure

1. Run the calibration home position program Detailed in section Checking the
twice. calibration position on page 225.
Do not change the position of the manipulator
axes after running the program!
2. Check the calibration positions. Detailed in section Checking the
Check the calibration positions of axes 6, 2 and calibration position on page 225.
5. If axes 5 and 6 are within the tolerances given
below, then axes 3 and 4 do not need to be
checked. The acceptable accurancy is:
• axis 2, 3: ±0.20 mm/m
• axis 4, 5, 6: ±0.40 mm/m
If the axes are outside the tolerance, start the
calibration procedure from the beginning, in
increasing sequence of the axes.
3. Repeat the check as above.
4. Adjust the calibration marks when the calibra- Shown in section Calibration
tion is done. scales and correct axis position
on page 222.
5. The system parameters will be saved to the stor-
age 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.
250 Revision - 3HAC 022032-001

6 Calibration, M2004
6.0.1 Introduction
6: Calibration, M2004
6.0.1 Introduction
Calibration 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.
3HAC 022032-001 Revision - 251

6 Calibration, M2004
6.0.1 Introduction
252 Revision - 3HAC 022032-001

Index
C
Calibration position, 248
R
Revolution counters, 248
U
Updating revolution counters, 248
3HAC 022032-001 253

Index
254 3HAC 022032-001

IRC5-IRB4400 Prod Man Part1 3HAC022032-001 - Procedures - Rev - en PDF

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Product manual, procedures

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2: Installation and commissioning 33

4.6: Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180

6: Calibration, M2004 251

About this This manual contains instructions for

Usage This manual should be used during

Who should read This manual is intended for:

Prerequisites The reader should...

Organization of The manual is organized in the following chapters:

3HAC 022032-001 Revision - 7

8 Revision - 3HAC 022032-001

0.0.2 Reading the product manual

Step Action Note/Illustration

Step Action Note/Illustration

3HAC 022032-001 Revision - 9

Symbol Designation Signification

TIP Tip symbols advice you to specific instructions,

ELECTRICAL SHOCK The electrocution or electrical shock symbol indi-

10 Revision - 3HAC 022032-001

0.0.3 Product documentation, M2000

3HAC 022032-001 Revision - 11

12 Revision - 3HAC 022032-001

0.0.4 Product documentation, M2004

3HAC 022032-001 Revision - 13

14 Revision - 3HAC 022032-001

3HAC 022032-001 Revision - 15

1.1: General information

1.1.1 Safety, service - General

16 Revision - 3HAC 022032-001

1.1.2 Limitation of Liability

3HAC 022032-001 Revision - 17

1.1.3 Related information

Type of information Detailed in document Section

18 Revision - 3HAC 022032-001

1.2: Safety risks

1.2.1 Safety risks related to gripper

3HAC 022032-001 Revision - 19

1.2.2 Safety risks related to tools/workpieces

20 Revision - 3HAC 022032-001

1.2.3 Safety risks related to pneumatic/hydraulic systems

General Special safety regulations apply to pneumatic and hydraulic systems.

3HAC 022032-001 Revision - 21

1.2.4 Safety risks during operational disturbances

22 Revision - 3HAC 022032-001

1.2.5 Safety risks during installation and service

3HAC 022032-001 Revision - 23

1.2.6 Risks associated with live electric parts

24 Revision - 3HAC 022032-001

1.3: Safety actions

1.3.1 Safety fence dimensions

3HAC 022032-001 Revision - 25

1.3.2 Fire extinguishing

26 Revision - 3HAC 022032-001

1.3.3 Emergency release of the manipulator’s arm

3HAC 022032-001 Revision - 27

1.3.4 Brake testing

28 Revision - 3HAC 022032-001

1.3.5 Risk of disabling function "Reduced speed 250 mm/s"

3HAC 022032-001 Revision - 29

1.3.6 Safe use of the Teach Pendant Unit

30 Revision - 3HAC 022032-001

1.3.7 Work inside the manipulator’s working range