Professional Documents
Culture Documents
IRC5-IRB4400 Prod Man Part1 3HAC022032-001 - Procedures - Rev - en PDF
IRC5-IRB4400 Prod Man Part1 3HAC022032-001 - Procedures - Rev - en PDF
Articulated robot
IRB 4400 - 45
IRB 4400 - 60
IRB 4400 - L10
IRB 4400 - L30
IRB 4400 - LS
M2000, M2004
Product manual, procedures
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.
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
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
4 3HAC 022032-001
Table of Contents
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
5.3.5 Calibration, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
5.3.6 Calibration, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
5.3.7 Calibration, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
5.3.8 Calibration, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
5.3.9 Updating the revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
5.4: After calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
5.4.1 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
3HAC 022032-001 5
Table of Contents
6 3HAC 022032-001
0.0.1 Overview
0.0.1 Overview
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
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.
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.
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.
Danger levels The table below defines the captions specifying the danger levels used thoughout this manual.
Note
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:
Product manual, procedures
• 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.
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:
Product manual, procedures
• 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
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)
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)
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.
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.
General The list below specifies documents which contain useful information:
Documents
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.
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.
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.
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.
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
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.
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!
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.
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.
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.
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.
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
L - Long arm
S - Shelf mounted manipulator
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
Loads on founda-
tion, manipulator Z
IRB 4400/S
0-30º
X
30º
X’
Z’ Z X
xx0300000255
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
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
Extreme posi- The illustration below shows the extreme positions of the robot arms IRB 4400/45 and /60:
tions 53
R1
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
Robot motion The table below specifies the types and ranges of the robot motion in every axis.
Extreme posi- The illustration below shows the extreme positions of the robot arm IRB 4400/L30:
tions C 53
R1
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
Robot motion The table below specifies the types and ranges of the robot motion in every axis.
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
Robot motion The table below specifies the types and ranges of the robot motion in every axis.
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
Robot motion The table below specifies the types and ranges of the robot motion in every axis.
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.
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.
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
Lifting The procedure below details how to lift the complete manipulator (IRB 4400/S).
instruction, IRB
4400/S
Step Action Note/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.
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!
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
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!
R1.SMB
0V B14
+24V B16
xx0300000200
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
Step Action Note/Illustration
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!
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.
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
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!
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
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/L10.
4400/L10
The shaded area indicates the permitted positions (center of gravity) for any extra equipment
mounted in the holes.
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)
Fitting equipment The illustration below shows the mounting holes available for fitting extra equipment on the
on gearbox unit gearbox unit.
The shaded area indicates the permitted positions (center of gravity) for any extra equipment
mounted in the holes.
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
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
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.
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 .
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.
Additional stops The additional stops are fitted as shown in the figure below.
D
E
F
C
xx0300000258
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
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
Equipment, etc. Spare part no. Art. no. Note
Mechanical stop, axis 2 3HAC 4225-1 Includes spacers, damp-
ers, attachment screws
and nuts.
Spacer (damper) 3HAB 9185-1
Spacer 3HAC 3962-1
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
in the Product manual, ref-
erence 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.
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
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.
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.
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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.
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.
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.
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.
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
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.
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.
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
Connection sets To connect power and signal conductors to the manipulator base/upper arm connectors, the
following parts are recommended.
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
Customer Contact on
Customer
Customer Contact Manipulator base
Signal name Terminal
on Upper arm, R2 (cable between manipulator
Controller
and controller not supplied)
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
and controller not supplied)
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
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.
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.
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!
Location of The mechanical stop on axis 1 is located on the frame as shown in the figure below.
mechanical stop
xx0300000182
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Warning!
If the mechanical stop has been deformed after a hard collision, it must be replaced!
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Battery pack 4944 026-4 Rechargeable nickel-
cadmium battery.
Battery pack 3HAC 16831-1 Lithium battery.
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard tool-
kit in the Product manual,
reference information.
Other tools and procedures These procedures
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.
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
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!
General The oil in the gearbox unit, axis 1-2-3, is normally not changed. This section specifies the oil
permitted in the unit.
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
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
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
in the Product manual, ref-
erence information .
Inspection, oil The procedure below details how to inspect the oil level of the gearbox unit, axes 2-3.
level axis 2-3
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!
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.
5. Refit the oil plug.
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)
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Lubricating oil 3HAC 0860-1 Optimol Optigear BM 100
Volume: 3,400 ml.
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
in the Product manual, ref-
erence information.
Oil collecting vessel Capacity: 4,000 ml.
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.
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.
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!
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!
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!
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
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
Equipment, etc. Spare part no. Art. no. Note
Lubricating oil 3HAC 0860-1 Optimol Optigear BM 100
Volume: 3,400 ml
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
in the Product manual, ref-
erence information.
Oil collecting vessel Capacity: 4,000 ml
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.
Draining oil The procedure below details how to drain the oil from the wrist unit (axis 5 and 6).
Tip!
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
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!
Filling oil The procedure below details how to fill oil to the wrist unit (axis 5 and 6).
Note!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may differ from the specified amount, depending on how much
oil has previously been drained from the gearbox.
Warning!
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
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
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Lubricating oil 3HAC 0860-1 Optimol Optigear BM 100
Volume: 800 ml
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
in the Product manual,
reference information.
Oil collecting vessel Capacity: 1000 ml
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.
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!
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
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!
Filling oil The procedure below details how to fill oil to the wrist unit (axis 5 and 6), robot version IRB
4400/L10.
Note!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may differ from the specified amount, depending on how much
oil has previously been drained from the gearbox.
Warning!
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
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
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.
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
Equipment, etc. Spare part no. Art. no. Note
Leakdown tester 3HAC 0207-1
Leak detection spray
Procedure
General This section details how to mount and grease different types of bearings on the manipulator.
Equipment
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.
General This sections details how to mount different types of seals to the manipulator.
Equipment
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.
Flange seals and The procedure below details how to fit flange seals and static seals.
static seals
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
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
Required
equipment
Equipment, etc. Art. no. Note
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-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference information.
Removal, cabling The procedure below details how to remove the cable harness from the axes 1-3.
axes 1-3
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
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.
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
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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.
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in
the Product manual, refer-
ence 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.
Refitting, cabling The procedure below details how to refit the cable harness to axes 1-3.
axes 1-3
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
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.
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.
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.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information .
F
I
J
X X
B
xx0300000112
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
Required
equipment
Equipment, etc. Art. no. Note
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-
step instructions below.
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference information .
Removal, cabling The procedure below details how to remove the cable harness from the axes 4-6.
axes 4-6
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The cable packs are sensitive to mechanical damage! They must be handled with care, 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.
A
xx0300000113
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.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information .
F
I
J
X X
B
xx0300000112
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Cable harness, axes 4-6 3HAC 7822-1
Gasket 3HAC 3676-1 3 pcs
Between the motor and the
connection box.
Replace if damaged.
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
in the Product manual, ref-
erence 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.
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
Refitting, cabling The procedure below details how to refit the cable harness to the axes 4-6.
axes 4-6
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The cable packs are sensitive to mechanical damage! They must be handled with care, 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.
A
xx0300000113
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.
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
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard tool-
kit in the Product man-
ual, reference
information.
Other tools and procedures These procedures
may be required. See refer- include references to the
ences to these procedures tools required.
in the step-by-step instruc-
tions below.
Removal, com- The procedure below details how to remove the complete arm system from the manipulator.
plete arm system
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The complete arm system weighs xx kg! All lifting equipment used must be dimensioned
accordingly!
xx0300000142
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
Equipment, etc. Spare part no. Art. no. Note
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.
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
in the Product manual,
reference information.
Refitting, com- The procedure below details how to refit the complete arm system to the manipulator.
plete arm system
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The complete arm system weighs xx kg! All lifting equipment used must be dimensioned
accordingly!
xx0300000142
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.
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
in the Product manual, reference information!
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
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in
the Product manual, refer-
ence information.
Dismounting tool 3HAC 0163-1 Used to pull out the shaft.
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.
Removal, upper The procedure below details how to remove the complete upper arm from the manipulator.
arm
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The complete upper arm weighs xx kg without any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!
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
in the Product manual, reference information!
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
Equipment, etc. Spare part no. Art. no. Note
Sealing ring 3HAC 7877-1
Taper roller bearing 3HAA 2103-13
VK cover 3HAC 12165-1
Refitting, upper The procedure below details how to refit the complete upper arm to the manipulator.
arm
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The complete upper arm weighs xx kg without any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!
• 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
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.
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!
A more detailed view of the component and its position may be found in the Foldout section
in the Product manual, reference information!
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
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in
the Product manual, refer-
ence 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.
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.
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.
A
xx0300000148
xx0300000149
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!
A more detailed view of the component and its position may be found in the Foldout section
in the Product manual, reference information!
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
Equipment, etc. Spare part no. Art. no. Note
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)
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!
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.
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.
A
xx0300000148
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.
Refitting, wrist The procedure below details how to refit the wrist unit to robot version IRB 4400/L10.
unit IRB 4400/L10
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.
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.
B B
xx0300000153
xx0300000149
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.
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 more detailed view of the component and its position may be found in the Foldout section
in the Product manual, reference information!
A B
xx0300000183
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Arm house unit 3HAC 16670-1 Includes axis 4 hous-
ing, upper arm tube,
motors.
Arm house unit 3HAC 17542-1
(Foundry)
Standard toolkit 3HAC 17594-1 The contents are
defined in section Stan-
dard toolkit in the Prod-
uct manual, reference
information..
Replacement, The procedure below details how to replace the arm house unit.
arm house unit
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The complete arm house unit weighs 152 kg! All lifting equipment used must be dimensioned
accordingly!
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.
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
in the Product manual, reference information!
A
x
C
x
B
A
x-x
xx0300000176
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Mechanical stop, axis 4 3HAB 8856-1
Damper 3HAB 3760-1
Flange sealing 1234 0011-116 Loctite 574
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.
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Warning!
If the mechanical stop has been deformed after a hard collision, it must be replaced!
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
Refitting, The procedure below details how to refit the axis 4 mechanical stop to the manipulator.
mechanical stop
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
Equipment, etc. Spare part no. Art. no. Note
Customer connection axis 4 3HAC 8820-1 Includes signal/power
cabling, necessary
brackets, holders etc.
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard tool-
kit in the Product manual,
reference information..
Other tools and procedures These procedures
may be required. See refer- include references to the
ences to these procedures tools required.
in the step-by-step instruc-
tions below.
Removal, signal The procedure below details how to remove the signal cabling from the upper arm.
cabling upper
arm
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Refitting, signal The procedure below details how to refit the signal cabling to the upper arm.
cabling upper
arm
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
xx0300000193
• A: 2 pcs, M8x12.
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!
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.
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
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard tool-
kit in the Product manual,
reference information..
Measuring tool, play 3HAC 1611-6
(IRB 4400/45, /60, /L30, /S)
Measuring tool, play 3HAB 6337-1
(IRB 4400/L10)
Other tools and procedures These procedures
may be required. See refer- include references to the
ences to these procedures tools required.
in the step-by-step instruc-
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!
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.
A
xx0300000186
A
xx0300000187
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
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are
defined in section Stan-
dard toolkit in the Prod-
uct manual, reference
information..
Measuring tool, play 3HAB 1611-6
(IRB 4400/45, /60, /L30, /S)
Measuring tool, play 3HAB 6337-1
(IRB 4400/L10)
Other tools and procedures These procedures
may be required. See refer- include references to the
ences to these procedures in tools required.
the step-by-step instructions
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!
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.
m
A
xx0300000188
A
xx0300000189
A
F
xx0300000190
Location of lower The lower arm 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
in the Product manual, reference information!
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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.
Removal, lower The procedure below details how to remove the lower arm from the manipulator.
arm
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The lower arm weighs 68 kg! All lifting equipment used must be dimensioned accordingly!
Location of lower The lower arm 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
in the Product manual, reference information!
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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.
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.
Calibration Pendulum Instruc- Art. no. is specified in
tion section Document ref-
erences in the Product
manual, reference
information.
Refitting, lower The procedure below details how to refit the lower arm to the manipulator.
arm
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The lower arm weighs 68 kg! All lifting equipment used must be dimensioned accordingly!
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.
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
in the Product manual, reference information!
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
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in
the Product manual, refer-
ence information.
Puller tool 2 pcs
Used to pull out the tie rod
alternately at the upper and
lower end if the tie rod.
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.
Removal, tie rod The procedure below details how to remove the tie rod from the manipulator.
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.
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
in the Product manual, reference information!
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
Equipment, etc. Spare part no. Art. no. Note
Washer 3HAB 3704-1 Replace if damaged.
Refitting, tie rod The procedure below details how to refit the tie rod on to the manipulator.
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.
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.
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
in the Product manual,
reference information.
Lifting tool 3HAB 1412-1 Used to lift the parallel
arm.
Other tools and procedures These procedures include
may be required. See refer- references to the tools
ences to these procedures required.
in the step-by-step instruc-
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!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The 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!
xx0300000127
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
in the Product manual, reference information!
E F
D
xx0300000128
A Parallel arm
B Attachment screw
C Washer
D V-ring on parallel arm
E Bearing
F Sealing
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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.
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in
the Product manual, refer-
ence information.
Lifting tool 3HAB 1412-1
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.
Calibration Pendulum Art. no. is specified in sec-
Instruction tion Document references
in the Product manual, ref-
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!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The 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!
xx0300000127
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.
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
.
Securing front screws M10x40H
H= threaded to the head.
Used to unload the bal-
ancing device before
removal.
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.
Removal, bal- The procedure below details how to remove the balancing device.
ancing device
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.
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!
xx0300000088
• A: Approximately 2º
2. Remove the two securing screws (A),
located at the fork of the balancing device. B
xx0300000089
xx0300000095
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!
The balancing device weighs 50 kg!
xx0300000099
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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.
Standard toolkit 3HAC 17594-1 The contents are defined in
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!
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.
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!
xx0300000089
xx0300000095
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
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.
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
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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
Standard toolkit 3HAC 17594-1 The contents are
defined in section Stan-
dard toolkit .
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.
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!
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.
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.
Refitting, serial The procedure below details how to refit the complete serial measurement unit.
measurement
unit
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.
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
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
Equipment, etc. Spare part no. Art. no. Note
Pushbutton unit 3HAC 0017-1
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit.
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.
Calibration Pendulum Art. no. is specified in sec-
Instruction tion Document references
.
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.
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.
Removal, push- The procedure below details how to remove the pushbutton unit from the manipulator.
button unit
Refitting of push- The procedure below details how to refit the pushbutton unit to the manipulator.
button unit
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Mechanical stop, axis 1 3HAB 3647-1
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
.
Other tools and procedures These procedures include
may be required. See refer- references to the tools
ences to these procedures required.
in the step-by-step instruc-
tions below.
Replacement, The procedure below details how to replace the mechanical stop pin on axis 1.
mechanical stop
pin
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Warning!
If the mechanical stop has been deformed after a hard collision, it must be replaced!
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 more detailed view of the component and its position may be found in the Foldout section
in the Product manual, reference information!
A
xx0300000154
A Motor, axis 1
B Connection box with cover
C Attachment screws and washers
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in
the Product manual, refer-
ence 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.
Circuit Diagram See chapter Circuit dia-
grams in the Product man-
ual, reference information
Removal, motor The procedure below details how to remove the motor, axis 1.
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
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.
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 more detailed view of the component and its position may be found in the Foldout section
in the Product manual, reference information!
A
xx0300000154
A Motor, axis 1
B Connection box with cover
C Attachment screws and washers
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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
Flange sealing 1234 0011-116 Loctite 574
Gasket 3HAC 4432-1 Between the motor
and the connection
box.
Replace if damaged.
Refitting, motor The procedure below details how to refit the motor, axis 1.
axis 1
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Note!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
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!
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.
Location of motor The motor, axis 2, is located as shown in the figure below.
The motor and the drive gear constitute one unit.
A more detailed view of the component and its position may be found in the Foldout section
in the Product manual, reference information!
xx0300000159
A Motor, axis 2
B Connection box
C Attachment screws and washers
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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 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
Removal, motor The procedure below details how to remove the motor, axis 2.
axis 2
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Note!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Danger!
Location of motor The motor, axis 2, is located as shown in the figure below.
The motor and the drive gear constitute one unit.
A more detailed view of the component and its position may be found in the Foldout section
in the Product manual, reference information!
xx0300000159
A Motor, axis 2
B Connection box
C Attachment screws and washers
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Motor unit, axis 2 3HAC 5954-1 Includes pinion.
O-ring 2152 0431-11
Flange sealing 1234 0011-116 Loctite 574
Standard toolkit 3HAC 17594-1 The contents are 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 Choose one of the two tools.
3HAB 1408-1
Refitting, motor The procedure below details how to refit the motor, axis 2.
axis 2
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Note!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
C
xx0300000160
• A: Upper screw
• B: Lower screw
• C: Pushing direction
7. Adjustment is detailed in section
Adjustment of motors, axes 1-3
on page 196.
Note!
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.
Location of motor The motor, axis 3, is located as shown in the figure below.
The motor and the drive gear constitute one unit.
A more detailed view of the component and its position may be found in the Foldout section
in the Product manual, reference information!
xx0300000163
A Motor, axis 3
B Connection box
C Attachment screws and washers, motor
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard tool-
kit in the Product manual,
reference information!
Other tools and procedures These procedures
may be required. See refer- include references to the
ences to these procedures tools required.
in the step-by-step instruc-
tions below.
Circuit Diagram See the chapter Circuit
diagrams in the Product
manual, reference infor-
mation.
Removal, motor The procedure below details how to remove the motor, axis 3.
axis 3
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Note!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Danger!
Location of motor The motor, axis 3, is located as shown in the figure below.
The motor and the drive gear constitute one unit.
A more detailed view of the component and its position may be found in the Foldout section
in the Product manual, reference information!
xx0300000163
A Motor, axis 3
B Connection box
C Attachment screws and washers, motor
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Motor unit, axis 3 3HAC 5954-1 Includes pinion.
O-ring 3HAC 2152 0431-11
Flange sealing 1234 0011-116 Loctite 574
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
in the Product manual,
reference information!
Power supply 24 VDC, 1.5 A
To be used for releasing
the brakes.
Measuring tool 3HAB 7887-1 or Choose one of the two
3HAB 1408-1 tools.
Refitting, motor The procedure below details how to refit the motor, axis 3.
axis 3
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Note!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
C
xx0300000160
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.
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 1 on page 182
• Refitting of motor, axis 2 on page 188
• Refitting of motor, axis 3 on page 193.
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in the
Product manual.
Measuring tool 3HAB 7887-1 or Choose one of the tools. They
3HAB 1408-1 or are all compatible with the
motor.
Power supply 24 VDC, 1.5 A
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.
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.
A more detailed view of the component and its position may be found in the Foldout section
in the Product manual, reference information!
D A
x
B
E
C
x-x
xx0300000164
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are defined
in section Standard toolkit
in the Product manual,
refernce 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.
Removal, motor The procedure below details how to remove the motors of axes 4, 5 and 6.
axes 4, 5 and 6
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Note!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Danger!
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,
in the Product manual, reference information!
D A
x
B
E
C
x-x
xx0300000164
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Motor unit, axis 4 3HAC 10603-1 Includes pinion.
O-ring 2152 2012-426
Gasket 3HAC 3676-1 3 pcs
Between the motors and the
connection box.
Replace if damaged.
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in
the Product manual,
refernce information.
Refitting, motor The procedure below details how to refit the motor, axis 4.
axis 4
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Note!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
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.
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
in the Product manual, reference information!
D A
x
B
E
C
x-x
xx0300000164
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Motor unit, axis 5 3HAC 10603-1 Includes pinion.
(IRB 4400/45, /60, /L30,
/S)
Motor unit, axis 5 3HAC 10605-1 Includes pinion.
(IRB 4400/L10)
O-ring 2152 2012-426
Gasket 3HAC 3676-1 3 pcs
Between the motor and the
connection box.
Replace if damaged.
Refitting, motor The procedure below details how to refit the axis 5 motor.
axis 5
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Note!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
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.
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
in the Product manual, reference information!
D A
x
B
E
C
x-x
xx0300000164
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Motor unit, axis 6 3HAC 10604-1 Includes pinion.
(IRB 4400/45, /60, /L30, /S)
Motor unit, axis 6 3HAC 10605-1 Includes pinion.
(IRB 4400/L10)
O-ring 2152 2012-426
Gasket 3HAC 3676-1 3 pcs
Between the motors and
the connection box.
Replace if damaged.
Refitting, motor The procedure below details how to refit the axis 6 motor.
axis 6
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Note!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
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.
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
Standard toolkit 3HAC 17594-1 The contents are
defined in section Stan-
dard toolkit in the Prod-
uct manual, reference
information!
Lifting slings with hoisting Lifting capacity: 500 kg.
block
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.
Removal, The procedure below details how to remove the gearbox unit, axis 1-2-3, including the
gearbox unit motors, from the manipulator.
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The 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!
xx0300000172
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.
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
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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.
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in
the Product manual, refer-
ence information!
Lifting slings with hoist- Lifting capacity: 500 kg.
ing block
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.
Calibration Pendulum Art. no. is specified in section
Instruction Document references in the
Product manual, reference
information.
Refitting, gearbox The procedure below details how to refit the gearbox unit, including motors, to the manipu-
unit lator.
Warning!
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Caution!
The 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!
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.
Tightening torque: 260 Nm.
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.
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.
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
Equipment, etc. Spare part no. Art. no. Note
Flange sealing 1234 0011-116 Loctite 574
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in
the Product manual, refer-
ence 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.
Adjusting play, The procedure below details how to adjust the play for the intermediate gear of axis 4.
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.
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
5.1: Overview
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:
Peripheral The robot must be free from any peripheral equipment during calibration. Fitted tools and
equipment similar will cause erroneous calibration positions.
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.
Introduction This section specifies the calibration scale positions and/or correct axis position for all robot
models.
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.
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
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
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
xx0100000196
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
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
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!
- 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
Measuring units
Installation of
sensor
Step Action Info/Illustration
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.
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
xx0100000194
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
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
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.
- 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
Required
equipment
Equipment Art. no. Note
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
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.
Calibration of The special calibration equipment is fitted to the base of the manipulator as shown in the
axis 1 figure below.
A
xx0300000202
Required
equipment
Equipment, etc. Spare part no. Art. no. Note
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 !
B
xx0300000203
General This section details how to perform the actual fine calibration of axis 2 using the Wyler cali-
bration equipment.
Required
equipment
Equipment Art. no. Note
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
Tip!
General This section details how to perform the actual fine calibration of axis 3 using the Wyler cali-
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.
these procedures in the step-by-
step instructions below.
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
Tip!
General This section details how to perform the actual fine calibration of axis 4 using the Wyler cali-
bration equipment.
Required
equipment
Equipment Art. no. Info
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
Tip!
General This section details how to perform the actual fine calibration of axis 5 using the Wyler cali-
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
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.
these procedures in the step-by-
step instructions below.
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
Tip!
General This section details how to perform the actual fine calibration of axis 6 using the Wyler cali-
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
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 These procedures include references to
may be required. See refer- the tools required.
ences to these procedures in
the step-by-step instructions
below.
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
Tip!
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
Step Action Illustration
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!
xx0100000194
xx0100000201
xx0100000202
General Perform the following procedure after calibrating any manipulator axes. The procedure is
intended to verify that all calibration positions are correct.
Procedure
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.
C
Calibration position, 248
R
Revolution counters, 248
U
Updating revolution counters, 248