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6 Reference information

6.8. Lifting equipment and lifting instructions

3HAC022031-001 Revision: C

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6.8. Lifting equipment and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting equipment, which

are specified in each procedure.

The use of each piece of lifting equipment is

not

detailed in the activity procedure, but in the

instruction delivered with each piece of lifting equipment.

This implies that the instructions delivered with the lifting equipment should be stored for

later reference.

Summary of Contents for IRB 2400/L

Page 1: ...Product manual Articulated robot IRB 2400 L IRB 2400 10 IRB 2400 16 M2000 M2000A M2004 ...

Page 2: ......

Page 4: ...sons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravent...

Page 5: ...orking range 30 1 2 3 8 Translate the information on safety and information labels 31 1 3 Safety related instructions 32 1 3 1 Safety signals general 32 1 3 2 DANGER Moving robots are potentially lethal 34 1 3 3 DANGER First test run may cause injury or damage 35 1 3 4 WARNING The unit is sensitive to ESD 36 1 3 5 WARNING Safety risks during work with gearbox oil 37 2 Installation and commissionin...

Page 6: ...ent of complete upper arm 102 4 5 Lower arm 106 4 5 1 Replacement of complete lower arm 106 4 5 2 Replacement of tie rod 110 4 6 Frame and base 114 4 6 1 Replacement of SMB unit 114 4 6 2 Replacement of brake release unit 117 4 6 3 Replacement of parallel arm 119 4 7 Motors 122 4 7 1 Replacement of motor axis 1 122 4 7 2 Replacement of motor axis 2 127 4 7 3 Replacement of motor axis 3 132 4 7 4 R...

Page 7: ...ipment and lifting instructions 180 7 Spare parts and exploded views 181 7 1 Introduction 181 7 2 Spare parts base 182 7 3 Spare parts lower arm 184 7 4 Spare parts upper arm IRB 2400 10 16 189 7 5 Spare parts upper arm IRB 2400 L 191 7 6 Spare parts drive unit IRB 2400 L 193 7 7 Spare parts customer cable axis 4 194 7 8 Spare parts limit switch 195 8 Circuit diagram 197 8 1 Introduction 197 Index...

Page 9: ...repair maintenance work Organization of chapters The manual is organized in the following chapters Chapter Contents Safety service Safety information that must be read through before performing any installation or service work on robot Contains general safety aspects as well as more specific information about how to avoid personal injuries and damage to the product Installation and commissioning R...

Page 10: ...s 3HAC17076 1 Application manual Additional axes and stand alone controller 3HAC021395 001 M2004 Application manual External axes 3HAC9299 1 M2000 Document name Document ID CalibWare 2 0 Users Guide M2000 3HAC16090 1 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 mate...

Page 11: ...ew 9 3HAC022031 001 Revision C Copyright 2004 2008 ABB All rights reserved C Cleanroom added Changes made in Prerequisites in section Overview Oil change in section Maintenance Revision Description Continued ...

Page 12: ...e references to equipment spare parts tools etc required for the different actions in the procedure The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information that is article number dimensions The denomination in the procedure for the component or attachment point corresponds to the denomination in...

Page 13: ...procedures including spare parts Additional procedures if any calibration decommissioning Reference information article numbers for documentation referred to in Product manual procedures lists of tools safety standards Part list Foldouts or exploded views Circuit diagrams Software manuals The software documentation consists of a wide range of manuals ranging from manuals for basic understanding of...

Page 14: ...ures including spare parts Additional procedures if any calibration decommissioning Reference information article numbers for documentation referred to in Product manual procedures lists of tools safety standards Part list Foldouts or exploded views Circuit diagrams Technical reference manuals The following manuals describe the robot software in general and contain relevant reference information R...

Page 15: ... first hand operational contact with the robot that is production cell operators programmers and trouble shooters The group of manuals includes Emergency safety information General safety information Getting started IRC5 and RobotStudio Online IRC5 with FlexPendant RobotStudio Online Introduction to RAPID Trouble shooting IRC5 for the controller and robot Continued ...

Page 17: ... to attend to before performing any service work on the robot These are applicable for all service work and are found in section General safety information on page 16 specific safety information pointed out in the procedure at the moment of the danger How to avoid and eliminate the danger is either detailed directly in the procedure or further detailed in separate instructions found in section Saf...

Page 18: ...robot described in the applicable documents for example User s Guide S4Cplus M2000 Operating Manual IRC5 with FlexPendant M2004 Product Manual Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices Via this interface an external safety function can interact with other machines and per...

Page 19: ...t be crossed before admittance must be set up in front of the robot s working space Light beams or sensitive mats are suitable devices Turntables or the like should be used to keep the operator out of the robot s working space The axes are affected by the force of gravity when the brakes are released In addition to the risk of being hit by moving robot parts you run the risk of being crushed by th...

Page 20: ...lt in burns too Removed parts may result in collapse of robot WARNING Take any necessary measures to ensure that the robot does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Safety risk Description Cable packs are sensitive to mechanical damage CAUTION The cable packs are sensitive to mechanical damage They must be handled with care especially th...

Page 21: ...safely turn off tools such as milling cutters etc 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 CAUTION Ensure that a gripper is prevented from dropping a workpie...

Page 22: ... to pneumatic and hydraulic systems Residual energy Residual energy may be present in these systems 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 p...

Page 23: ...rried out professionally and in accordance with the applicable safety regulations Care must be taken at all times Qualified personnel Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken d...

Page 24: ...side the robot s working space Voltage related risks controller S4Cplus A danger of high voltage is associated with the following parts Be aware of stored electrical energy DC link in the controller Units inside the controller e g I O modules can be supplied with power from an external source The mains supply mains switch The power unit The power supply unit for the computer system 230 VAC The rec...

Page 25: ...VAC The service outlets 115 230 VAC The customer power supply 230 VAC The power supply unit for additional tools or special power supply units for the machining process The external voltage connected to the controller remains live even when the robot is disconnected from the mains Additional connections Voltage related risks robot A danger of high voltage is associated with the robot in The power ...

Page 26: ...mension 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 ...

Page 27: ...e extinguishing 25 3HAC022031 001 Revision C Copyright 2004 2008 ABB All rights reserved 1 2 3 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the robot system robot or controller ...

Page 28: ...eased manually by pushing the brake release buttons on the robot How to release the brakes is detailed in section Manually releasing the brakes on page 45 The robot arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the...

Page 29: ...m its function How to test The function of the holding brake of each axis motor may be checked as detailed below 1 Run each robot axis to a position where the combined weight of the robot 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 robot does not ch...

Page 30: ...01 Revision C 28 Copyright 2004 2008 ABB All rights reserved 1 2 3 5 Risk of disabling function Reduced speed 250 mm s NOTE Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC This will affect the safety function Reduced speed 250 mm s ...

Page 31: ...released or pushed all the way in the robot is taken to the MOTORS OFF state To ensure safe use of the FlexPendant the following must be implemented The enabling device must never be rendered inoperative in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move The programmer must always bring the FlexPendant with him her when ...

Page 32: ...ntrol panel The robot s speed is limited to max 250 mm s when the operating mode selector is in position manual mode with reduced speed This should be the normal position when entering the working space The position manual mode with full speed 100 may only be used by trained personnel who are aware of the risks that this entails Pay attention to the rotating axes of the robot Keep a distance to th...

Page 33: ...o the product contain space for adding a fourth language underneath the three standard languages English German and French Add a local language to the label by Using a transparent sticker over the standard label with text added in a fourth language Drawings detailing the design text figure dimensions of the standard labels can be ordered from ABB Notice that each label is identified according to t...

Page 34: ...h for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc warning WARNING Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high volt...

Page 35: ...lectrostatic discharge ESD symbol indicates electrostatic hazards which could result in severe damage to the product Note NOTE Note symbols alert you to important facts and conditions Tip TIP Tip symbols direct you to specific instructions where to find additional information or how to perform a certain operation in an easier way Symbol Designation Signification Continued ...

Page 36: ...tion Action Note 1 Before attempting to run the robot make sure all emergency stop equipment is correctly installed and connected Emergency stop equipment such as gates tread mats light curtains etc 2 If possible use the hold to run function whenever possible The hold to run function is used in manual mode not in automatic mode How to use the hold to run function in RobotWare 5 0 is detailed in se...

Page 37: ... to take into consideration before the first test run Elimination Follow the procedure below when performing the first test run after a service activity repair installation or maintenance Action 1 Remove all service tools and foreign objects from the robot and its working area 2 Install all safety equipment properly 3 Make sure all personnel are standing at a safe distance from the robot that is o...

Page 38: ... induced electrical field When handling parts or their containers personnel not grounded may potentially transfer high static charges This discharge may destroy sensitive electronics Elimination Action Note 1 Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly 2 Use an ESD protective floor mat The mat must be grounded through a c...

Page 39: ...the opening Do not overfill the gearbox when filling Do not overfill Overfilling of gearbox oil can lead to internal over pressure inside the gearbox which in turn may damage seals and gaskets completely press out seals and gaskets prevent the robot from moving freely Make sure not to overfill the gearbox when filling with oil After filling check the correct oil level Do not mix types of oil Mixin...

Page 41: ...erved 2 Installation and commissioning 2 1 Introduction General This chapter contains information for installing the robot to the working site More detailed technical data such as load diagram permitted extra loads equipment and location of extra loads equipment may be found in the Product Specification for the robot ...

Page 42: ...he specifications in Storage conditions on page 41 5 Make sure the appointed operating environment of the robot conforms to the specifications outlined in Operating conditions on page 41 6 Before taking the robot to the installation site make sure the site conforms to Loads on foundation on page 40 Requirements foundation on page 41 and Protection classes on page 41 7 When these prerequisites are ...

Page 43: ...the robot system Forces and torques Endurance load operation Max load emergency stop Force xy 1700 N 2100 N Force z upright 4100 1100 N 4100 1400 N Force z suspended 4100 1100 N 4100 1400 N Torque Mxy 3000 Nm 3400 Nm Torque Mz 450 Nm 900 Nm Requirement Value Min levelity 0 5 mm Max tilt 5 Min resonance frequency 30 Hz Parameter Value Min ambient temperature storage 25 C Max ambient temperature sto...

Page 44: ...is section specifies the working areas of the robot models IRB 2400 L The working area is the same for both floor and inverted suspended Positions are located at wrist center xx0200000159 Pos X Z Angle axis 2 Angle axis 3 0 970 1620 0 0 1 404 2298 0 60 2 602 745 0 65 3 1577 246 110 60 4 400 403 110 24 5 5 1611 623 100 60 6 115 1088 100 65 Continues on next page ...

Page 45: ...0 Positions in the working range The table below specifies the positions inside the working range shown in the figure above Pos X Z Angle axis 2 Angle axis 3 0 855 1455 0 0 1 360 2041 0 60 2 541 693 0 65 3 1351 118 110 60 4 400 302 110 18 3 5 1350 624 100 60 6 53 1036 100 65 Position in figure Position mm Angles º X Z Axis 2 Axis 3 1 870 1139 0 0 2 510 1246 28 17 3 446 722 28 31 4 515 218 60 119 5...

Page 46: ...ipment Illustration attachment of lifting slings The figure below shows how to attach the lifting slings to the robot xx0200000164 Lifting of robot Equipment Note Sling line Type KDBK 7 8 Length 2 m Load at 90 380 kg Action Note 1 Move the robot to the lifting position shown in the figure above If necessary release the brakes as detailed in section Manually releasing the brakes on page 45 2 Attach...

Page 47: ...rocedure below details how to release the holding brakes using the internal brake release unit Action Note Illustration 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near the robot arm 2 If the robot is not connected to the controller power must be supplied to the connector R1 MP Detailed in section Supply...

Page 48: ...P in the robot base in order to enable the brake release unit on the robot Action Note Illustration 1 CAUTION Be careful not to interchange the 24 VDC and 0V pins If they are mixed up damage can be caused to a resistor diode and to the system board 2 Connect an external power supply to connector R1 MP at the robot base Supply 24 V on pin B8 0 V on pin C10 xx0200000167 3 Release the brakes with the...

Page 49: ...nt must be able to withstand the stress loads defined in section Loads on foundation on page 40 NOTE When the robot is to be mounted in a tilted or a suspended position the guide sleeves must be used to secure the bolted joint Attachment screws The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate foundation Hole configuration The fig...

Page 50: ...served Cross section guide sleeve hole The figure below shows the cross section of the guide sleeve holes from previous figure xx0200000182 Guide sleeves Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be remounted without re adjusting the program Equipment Art no Guide sleeves 2151 0024 169 Continued ...

Page 51: ... The robot can be mounted in a suspended position This section details how to turn the robot Turning the robot 1 Use the special tool for inverted mounting see following figure xx0200000212 2 Seal the eight holes in the bottom plate with plastic plugs see following figure xx0200000215 A Lifting beam B Fork lift Inverted mounting tool 3HAB8961 1 A Plastic plugs x8 ...

Page 52: ...ding motors gears and structure CAUTION Incorrect defined loads may result in operational stops or major damage on the robot 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 RobotWare 4 0 or Operating manual IRC5 with FlexPendant Stop time and braking di...

Page 53: ... there is a risk that it may collide with other objects its working space should be limited The working range of the following axes may be restricted Axis 1 hardware mechanical stop and position switch Axis 2 hardware mechanical stop Axis 3 hardware limit switch This section describes how to install hardware that restricts the working range Notice that adjustments must also be made in the software...

Page 54: ...g range of axis 1 can be restricted within the area from 50º to 140º as shown in the figure below The restrictions are made by fitting two extra stops to the robot base xx0500002105 Location of the mechanical stop axis 1 The extra mechanical stop is fitted to the robot base as shown in the figure below Note The stop must only be mounted in the direction shown below xx0200000205 1 Stop axis 1 remov...

Page 55: ...6 in scale 1 1 3 Use the template to mark the center of the two holes on each stop Place the template edge edge with the robot base as shown in the figure Location of where to drill holes for extra stops on page 54 4 Drill the holes through Ø 10 2 Cut threads M12 5 Fit the stops to the robot base but without tightening the screws Note The stops must be mounted in correct direction as shown in the ...

Page 56: ... for extra stops The figure below shows the drill pattern used when drilling for mechanical stops on axis 1 xx0200000206 9 WARNING If the mechanical stop is deformed after a hard collision it must be replaced Action Note A Maximum working range axis 1 B Minimum working range axis 1 C Drilling pattern enclosed with the mechanical stop D This mounting direction only Continued Continues on next page ...

Page 57: ...ribs and forbidden drilling sector xx0600002647 The minimum and maximum measurement between the mechanical stops The difference between the measurement and the minimum and maximum working range is 2 x 4º which corresponds to the width of the stop pin at the frame C Drilling not allowed inside this sector D Center lines for the hidden stiffening ribs Continued Continues on next page ...

Page 58: ...2 Installation and commissioning 2 4 2 Mechanically restricting the working range of axis 1 3HAC022031 001 Revision C 56 Copyright 2004 2008 ABB All rights reserved Drill template xx0200000207 Continued ...

Page 59: ...w shows the mechanical stops available The number of items that are needed for different working ranges are specified in the following table xx0200000208 Required equipment Working range Qty item 1 Qty item 2 Qty item 3 110 100 110 70 1 2 2 110 40 2 2 4 80 100 1 2 2 80 70 2 2 4 80 40 3 2 6 50 100 2 2 4 50 70 3 2 6 50 40 4 2 8 20 100 3 2 6 20 70 4 2 8 20 40 5 2 10 Equipment Art no Note Stop axis 2 ...

Page 60: ...3 Mechanically restricting the working range of axis 2 3HAC022031 001 Revision C 58 Copyright 2004 2008 ABB All rights reserved Standard toolkit The content is defined in section Standard toolkit on page 178 Equipment Art no Note Continued ...

Page 61: ...004 2008 ABB All rights reserved 2 4 4 Installation of limit switch axis 3 General The working range of axis 3 can be limited by fitting an electrical switch on the gearbox axis 3 which senses the position via a cam Mounting of eletrical stop Following illustration shows howe to fit the electrical stop xx0200000211 ...

Page 62: ...t 3HAC022031 001 Revision C 60 Copyright 2004 2008 ABB All rights reserved 2 5 Electrical connections 2 5 1 Connectors on robot Connectors on the robot The figure below shows all connections of the robot cabling including the customer connections xx0500002039 ...

Page 63: ...les supply to and feedback from any position switches on the robot Specified in the table Position switch cables robot base to controller option on page 62 Customer cables option Handles communication with equipment fitted on the robot by the customer low voltage signals and high voltage power supply protective ground See the product manual for the controller 1 External axes cables option Handles ...

Page 64: ... are completely pre manufactured and ready to plug in Cabling between robot base and controller Robot cable power 30 m 3HAC9038 4 Cable Art no Cable Art no Robot cable signal shielded 7 m 3HAC7998 1 Robot cable signal shielded 15 m 3HAC7998 2 Robot cable signal shielded 22 m 3HAC7998 3 Robot cable signal shielded 30 m 3HAC7998 4 Cable Art no Connection point robot Connection point cabinet Position...

Page 65: ...ion from the robot For example some articles in the robot s design which normally are exposed to some wear during operation are unpainted If replaced these articles must be replaced with new unpainted ones Cleanroom class 5 Particle emission from the robot fulfill Cleanroom class 5 standard according to DIN EN ISO 14644 1 Preparations before commissioning a Cleanroom robot During transport and han...

Page 67: ...ing intervals and refers to procedures for the activities Each procedure contains all information required to perform the activity that is required tools and materials The procedures are gathered in different sections and divided according to the maintenance activity Safety information Before any service work is commenced it is extremely important that all safety information is observed There are ...

Page 68: ...ance intervals Description The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot Calendar time specified in months regardless of whether the robot system is run or not Operating time specified in operating hours More frequent running of the robot means more frequent maintenance activities ...

Page 69: ... temperature over 40ºC 3 The battery is used as a back up when the robot system is switched off Therefore the life of a lithium battery depends on how frequently the power to the system is switched off and also if the environment temperature is higher than recommended operating temperature The life varies from 12 36 mths depending on current conditions An alert is given on the TPU or the FlexPenda...

Page 70: ... of oil Art no Amount Axis 1 Mobilgear 600 XP320 11712016 604 6 400 ml Axis 2 Mobilgear 600 XP320 11712016 604 4 500 ml Axis 3 Mobilgear 600 XP320 11712016 604 3 800 ml Axis 4 IRB 2400 L Mobilgear 600 XP320 11712016 604 30 ml Axis 4 IRB 2400 10 16 Optimol BM 100 3HAC 0860 1 1 500 ml Axis 5 and 6 IRB 2400 L Mobilgear 600 XP320 11712016 604 120 ml Axis 5 and 6 IRB 2400 10 16 Optimol BM 100 3HAC 0860...

Page 71: ... 16 The procedure below details how to drain the oil from the wrist unit A Oil plug B Oil plug air inlet when draining from oil plug A Equipment Art no Volume Note Lubricating oil IRB 2400 L 11712016 604 120 ml Mobilgear 600 XP320 Lubricating oil IRB 2400 10 16 3HAC 0860 1 800 ml Optimol BM 100 Oil collecting vessel Capacity 200 ml Standard toolkit The content is defined in section Standard toolki...

Page 72: ...in section WARNING Safety risks during work with gearbox oil on page 37 4 Remove the oil plugs in the wrist Shown in the figure Location of oil plugs gearbox axes 5 6 on page 69 5 Turn axis 4 through 90 so that the oil plug on the side of the wrist is pointing downwards xx0300000121 6 Then turn axis 4 another 90 7 Let the remaining oil run out through the hole on the tilt housing Action Note Illus...

Page 73: ...ks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 37 4 Fill oil in the hole located on the tilt housing axis 5 until the oil reaches up to the hole located on the side of the wrist 5 Note If the robot is mounted in suspension the wrist should be turned 180 6 Refit the oil plugs to the wrist Action Note Continued ...

Page 74: ...art no Note Battery unit 3HAC16831 1 Lithium battery This battery requires that the serial measurement unit 3HAC17396 1 is installed If instead serial measurement unit 3HAB 8413 1 is installed the battery 4944 026 4 must be used Gasket cover 3HAC3200 1 Always replace with a new one Standard toolkit The content is defined in section Standard toolkit on page 178 Other tools and procedures may be req...

Page 75: ...ive to ESD on page 36 3 Remove the rear cover plate A on the robot by unscrewing its attachment screws B xx0200000399 4 Remove the battery terminals from the serial measuring board and cut the clasp that keeps the battery unit in place 5 Fit the new battery with a clasp and connect the terminals to the serial measuring board Shown in the figure Location of SMB battery unit on page 72 6 Refit the c...

Page 77: ...he component location on the robot Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure The equipment is also gathered in different lists in the Product manual reference information The equipment is also gathered in different lists in the chapter Reference information Safety information Before any service work is commenced it...

Page 78: ...hich are included in the leakdown tester kit Art no is specified in Required equipment on page 76 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer Recommended value 0 2 0 25 bar 20 25 kPa 4 Disconnect the compressed air supply 5 Wait for approx 8 10 minutes No pressure loss must be detected If the compressed air is significantly colder o...

Page 79: ... 1 Used to grease the bearings if not specified otherwise Action Note 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 circumstanc...

Page 80: ...g 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 wi...

Page 81: ...ing over threads keyways etc Equipment etc Art no Note Grease 3HAB3537 1 Used to lubricate the seals Action Note 1 Check the seal to ensure that the seal is of the correct type provided with cutting edge there is no damage to the sealing edge feel with a fingernail 2 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced as it may result in future le...

Page 82: ... defective the parts may not be used because leakage could occur 2 Clean the surfaces properly and in accordance with ABB recommendations 3 Distribute the sealing compound evenly over the surface preferably with a brush 4 Tighten the screws evenly when fastening the flange joint Action Note 1 Ensure that the correct o ring size is used 2 Check the o ring for surface defects burrs shape accuracy et...

Page 83: ...r Spare parts and exploded views on page 181 in part 2 of the Product manual xx0200000396 Required equipment A Connectors behind the cover plate at the robot base R1 MP1 3 and R2 BU1 3 At the serial measurement board R2 G battery R2 FB1 3 B Connectors at motor 2 R3 MP2 and R3 FB2 C Connectors at motor 3 R3 MP3 R3 FB3 R3 LS1 and R3 LS2 D Connectors at motor 1 R3 MP1 R3 FB1 E Upper bracket F Cable g...

Page 84: ...es to these procedures in the step by step instructions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Action Note Illustration 1 In order to facilitate refitting of the cable harness move the robot to the specified position Axis 1 0 Axis 2 0 Axis 3 0 Axis 4 0 Axis 5 90 Axis 6 no significance Axes 2 and 3 may be tilted slightly to improve ac...

Page 85: ... from the connection R2 SMB1 4 C on the SMB unit xx0200000400 A R2 SMB B R2 SMB3 6 C R2 SMB1 4 8 Unscrew the four screws securing the cable gland This releases the cable harness from the frame 9 Remove the cable guide in the middle of the frame by removing the attachment screws of the holder A Remove the cables from the guide xx0200000404 Note Different robot versions are fitted with different ver...

Page 86: ...tly pull the cable harness out Action Note Illustration Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Gently pull down the cable harness through the center hole of axis 1 3 Fit a new gasket and fit the connection box on motor 1 2 and 3 using the three attachment screws The gasket is included in the spare part of the cable uni...

Page 87: ...oid cable failure 8 Secure the cabling inside the base Insert the cables in the sealing A Power cable B Power cable C Power cable D Customer cable E Signal cable F Signal cable Note Make sure that each cable is fitted in the same position as the old one otherwise the conduit entry will not be watertight Use six cable straps Note Always use a new sealing combined with a flange sealing Loctite 574 x...

Page 88: ...k of the cover xx0200000403 12 Connect the connectors R1 MP1 3 and R2 BU1 3 inside the base 13 Refit the rear cover plate A on the robot with its attachment screws B together with a new gasket xx0200000399 Spare part no is specified in Required equipment on page 81 14 If the battery has been disconnected from the SMB unit the revolution counters must be updated Detailed in section Updating revolut...

Page 89: ...se R1 MP1 3 R1 MP4 6 R1 CS R1 CP R1 H1 R2 BU R2 BU1 3 R2 BU4 6 a2 Connectors at the serial mesurement board SMB unit R2 SMB1 2 empty R2 G bat R2 FB1 3 and R2 FB4 6 B Connectors at motor 2 R3 MP2 and R3 FB2 C Connectors at motor 3 R3 MP3 R3 FB3 R3 LS1 and R3 LS2 D Connectors at motor 1 R3 MP1 R3 FB1 E Connectors at motor 4 5 kg option R3 MP4 and R3 FB4 e Connectors at motor 4 15 kg option R3 MP4 an...

Page 90: ...8mm Circuit Diagram See chapter Circuit diagram Standard toolkit The content is defined in section Standard toolkit on page 178 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure su...

Page 91: ... A between the battery B and the SMB unit C may stay connected in order to avoid recalibration of the robot Be careful not to let the weight of the SMB unit strain the cable In order to remove the SMB unit completely the connector R2 G must be disconnected This causes a necessary recalibration of the robot xx0200000398 7 Disconnect connector R2 FB 4 6 from the connection R2 SMB4 6 B on the SMB uni...

Page 92: ...d to avoid cable failure 10 Remove the upper bracket securing the cables to the arm house by unscrewing its two attachment screws C Cut the strip clamp B xx0200000405 11 Remove the back cover of the motors 4 6 fitted with torx screw 12 Disconnect all connectors at motor 4 5 and motor 6 R3 MP4 6 and R3 FB4 6 A R3 MP5 B R3 MP6 C R3 MP4 D R3 FB5 E R3 FB6 F R3 FB4 xx0200000406 13 Remove all screws hol...

Page 93: ...to the robot 2 In order to facilitate refitting of the cable harness run the robot to the specified position Axis 1 0 Axis 2 0 Axis 3 0 Axis 4 0 Axis 5 90 Axis 6 no significance Axes 2 and 3 may be tilted slightly to improve access 3 Gently pull down the cable harness through the center of the lower arm and through the hole of axis 1 4 Fit a new gasket and fit the motor case on motor 4 6 using the...

Page 94: ...04 2008 ABB All rights reserved 5 Reconnect all connectors at motor 4 5 and 6 R3 MP 4 6 A and R3 FB 1 3 B A R3 MP5 B R3 MP6 C R3 MP4 D R3 FB5 E R3 FB6 F R3 FB4 xx0200000406 xx0300000063 xx0300000062 6 Fit the back cover of the motors 4 6 Action Note Illustration Continued Continues on next page ...

Page 95: ...is used to avoid cable failure 9 Fit all the screws securing the cable gland This attaches the cable harness to the frame Cables A Power B Power C Power D Customer E Signal F Signal Note Make sure that each cable is fitted at the same position as the old ones otherwise the conduit entry will not be watertight Note Always use a new sealing and combine it with a flange sealing Loctite 574 xx02000004...

Page 96: ... SMB unit C may stay connected in order to avoid recalibration of the robot 12 Run all the earth cables on the R1 M4 6 cable to the back of the cover xx0200000403 13 Connect connectors R1 MP4 6 and R2 BU4 6 14 Refit the rear cover plate A on the robot with its attachment screws B xx0200000399 15 DANGER Make sure all safety requirements are met when performing the first test run These are further d...

Page 97: ...t 2004 2008 ABB All rights reserved 4 4 Upper arm 4 4 1 Replacement of wrist IRB 2400 10 16 Location of wrist The wrist is defined as the axis 5 and 6 of the robot This is shown in pos A in the figure below xx0300000103 A Wrist B Upper arm C Lower arm D Frame E Base Continues on next page ...

Page 98: ...398 1 O ring 3HAB3772 12 Replace if damaged Grease 3HAB3537 1 Shell Alvania WR2 Guide pins M8 length 70 mm Measuring tool 3HAB7887 1 Power supply 24 VDC 1 5 A For releasing the brakes Standard toolkit The content is defined in section Standard toolkit on page 178 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures in...

Page 99: ...t to the robot upper arm Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the oil plug on the wrist and drain it from all the oil Shown in the figure Wrist unit on page 96 3 Undo the attachment screws and remove the wrist Shown in the figure Wrist unit on page 96 Action Note Illustration 1 DANGER Turn off all electric power hydraulic ...

Page 100: ...rs for axes 5 and 6 detailed in section Replacement of motors axes 4 6 IRB 2400 10 16 on page 144 xx0200000425 A Gears on drive shaft unit axis 5 6 B Gears on the wrist 9 Tighten the attachment screws and washers Tightening torque 17 Nm 10 Check the play by moving axes 5 and 6 by hand 11 Refill the wrist unit with oil See the section Oil change gearbox axes 5 6 wrist unit on page 69 12 Recalibrate...

Page 101: ...elow x0300000409 Required equipment A Wrist B Upper arm C Lower arm D Frame E Base Equipment etc Spare part no Note Wrist 5 kg 3HAC10814 1 Standard and Foundry Locking liquid Loctite 574 Standard toolkit The content is defined in section Standard toolkit on page 178 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures...

Page 102: ...on the wrist Refitting wrist unit The procedure below details how to refit the wrist unit to the robot Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the oil plug from the wrist and drain it from all the oil x0300000104 A Screw B Oil plug air inlet C Wrist unit 3 Undo the screws and remove the wrist Action Note 1 DANGER...

Page 103: ...the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 159 9 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 35 Action Note Continued ...

Page 104: ...s 3 4 C Lower arm axis 2 D Frame axis 1 E Base Equipment Art no Note Lifting device upper arm Dismounting tool shaft ends 3HAB9009 1 Used for removing the shafts from the upper arm Mounting tool bearing 3HAB6464 1 Lifting tool chain To be used together with lifting eye M12 and lifting device upper arm Standard toolkit The content is defined in section Standard toolkit on page 178 Other tools and p...

Page 105: ...ectric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the tie rod Detailed in section Replacement of tie rod on page 110 3 Loosen the connectors of the motors of axes 4 5 and 6 Detailed in section Replacement of motors axes 4 6 IRB 2400L on page 137 4 Disconnect the connection box from the motors 5 Remove the covers Left Right Shown in the figure Upper arm attachment on page...

Page 106: ...fied in Required equipment on page 102 4 Raise the upper arm into the mounting position 5 Fit shaft spindles both sides 6 Insert the screws and tighten Tightening torque 90 Nm Shown in the figure Upper arm attachment on page 103 7 The following procedure must be performed within 10 minutes before the Loctite starts to harden Apply Loctite 243 on the KM nuts Fit and tighten the KM nut on the left s...

Page 107: ...led in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 159 11 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 35 Action Note Continued ...

Page 108: ...detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 181 in part 2 of the Product manual xx0200000409 Required equipment A Wrist B Upper arm C Lower arm D Frame E Base Equipment etc Spare part no Art no Note Lower arm 3HAC 4796 1 2400 10 16 Lower arm 3HAC 4797 1 2400L Sealing ring V ring 3HAB3732 13 Replace if damaged Bearing grease 3HAB353...

Page 109: ... also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the upper arm Detailed in s...

Page 110: ...5 Remove the tie rod Detailed in section Removal tie rod on page 112 6 Remove the parallel arm Detailed in section Removal parallel arm on page 120 7 Pull down the cabling from inside the lower arm and remove any cable attachments 8 Remove the attachment screws and the spring tension plate xx0200000440 A Attachment screws 9 Remove the lower arm Action Note Illustration Continued Continues on next ...

Page 111: ...jury to personnel 5 Lift the lower arm into position 6 Fit the spring tension plate to the lower arm and secure the arm to the gearbox with the 12 attachment screws 12 pcs M10 x 40 Tightening torque 72 Nm 7 Refit the parallel arm Detailed in section Refitting parallel arm on page 121 8 Refit the tie rod Detailed in section Refitting tie rod on page 112 9 Refit the upper arm Detailed in section Ref...

Page 112: ... 5 2 Replacement of tie rod Location of tie rod The tie rod is located as shown in the figure below A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 181 in part 2 of the Product manual xx0200000442 A Tie rod B Parallel arm Continues on next page ...

Page 113: ... Bearing sealing G Spherical roller bearing H Bearing sealing I Screw Equipment etc Spare part no Art no Note Locking liquid 3HAB7116 1 Loctite 243 Grease 3HAB3537 1 Press tool parallel bar bearing 3HAB6324 1 Mounting tool parallel bar 3HAB6331 1 Used to fit the tie rod Standard toolkit The content is defined in section Standard toolkit on page 178 Calibration Pendulum toolkit 3HAC15716 1 Complete...

Page 114: ...er arm weighs 23 kg without any additional equipment fitted Use a suitable lifting device to avoid injury to personnel 3 Use a crane to secure the weight of the upper arm Shown in the figure Location of tie rod on page 110 4 Remove the attachment screw from the upper and lower end Shown in the figure Location of tie rod on page 110 5 Remove the locking washer from both ends Shown in the figure Loc...

Page 115: ...s by hand Art no is specified in Required equipment on page 111 6 Fit new bearing sealings to the bearings 7 Refit the back up ring Shown in the figure Location of tie rod on page 110 8 Refit the locking washer Shown in the figure Location of tie rod on page 110 9 Refit the attachment screw at both ends of the bar using locking liquid M8 x 16 Loctite 243 Shown in the figure Location of tie rod on ...

Page 116: ... figure below A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 181 in part 2 of the Product manual Note that the robot is shown with the SMB cover already removed xx0200000451 Required equipment A Cable battery SMB board B Battery C Serial measurement board D Lock nuts Equipment Spare part no Art no Note Gasket base cover 3HAB 55...

Page 117: ...Circuit Diagram See chapter Circuit diagram Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment Spare part no Art no Note A Connector R2 SMB1 2 external axis B Connector R2 SMB1 4 C Connector R2 SMB3 6 D Connector to the battery unit R2 G E Connector R2 SMB Continued...

Page 118: ...ring the board 6 Gently disconnect the connectors from the SMB unit when pulling the board out Also disconnect the battery cable from the SMB unit All connectors are shown in the figure SMB unit layout on page 115 7 Gently connect the connectors to the new SMB unit and push the board in All connectors are shown in the figure SMB unit layout on page 115 8 Refit the SMB cover using the attachment lo...

Page 119: ... DSQC 563 3HAC16035 1 Standard toolkit The content is defined in section Standard toolkit on page 178 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action 1 DANGER If the robot normally works in an inverted position it must be removed from this position and placed on the...

Page 120: ...he base 6 Reconnect the cable to the new brake release unit and fit it to the base 7 Secure the unit with its six attachment screws on the outside of the base 8 Refit the cover to the rear of the base 9 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 35 Action Continue...

Page 121: ... part 2 of the Product manual xx0200000444 Required equipment A Tie rod B Parallel arm Equipment Spare part no Art no Note Groove ball bearing 3HAB3643 12 Sealing ring 3HAB5515 1 Bearing grease 3HAB3537 1 Standard toolkit The content is defined in section Standard toolkit on page 178 Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedure...

Page 122: ...w shows the assembly of the parallel arm xx0200000450 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the tie rod Detailed in section Removal tie rod on page 112 3 Remove the parallel arm by removing its eight attachment screws and washers A Parallel arm B Sealing V ring 2 pcs C Groove ball bearing D Attachment screws and washers 8 p...

Page 123: ...it it to the parallel arm 4 Fit the second V ring to the parallel arm 5 Fit the complete parallel arm to the robot with the eight attachment screws and washers 8 pcs M10x60 Tightening torque 72 Nm 6 Refit the tie rod Detailed in section Refitting tie rod on page 112 7 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibrat...

Page 124: ...motor axis 1 is located on the left hand side of the robot as shown in the figure below A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 181 in part 2 of the Product manual xx0200000465 A Cover B Connection box C Attachment screws and washers motor 4 pcs D Motor axis 1 E Correct orientation of holes Continues on next page ...

Page 125: ...ne Gasket 3HAB 3676 1 Measuring tool motor 3HAB7887 1 Power supply 24 VDC max 1 5 A For releasing the brakes Standard toolkit The content is defined in section Standard toolkit on page 178 Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instructions below Thes...

Page 126: ... 5 Use a marker pen to mark the position of the motor A if the same motor is to be refitted xx0600002646 6 Unscrew the four attachment screws and washers of the motor Shown in the figure Location of motor axis 1 on page 122 7 Gently lift the motor straight up making sure not to damage the motor pinion Action Note Illustration Action Note Illustration 1 DANGER Turn off all electric power hydraulic ...

Page 127: ...ere must always be some backlash meaning that the shaft should go easy to rotate 9 Place the tip of a dial indicator against the scribed mark on the measuring tool The tip of the dial indicator must measure on a 50 mm radius from the center of the motor shaft xx0200000473 A Measuring tool 10 Set the gear play to 0 02 mm which corresponds to a reading on the dial indicator of 0 13 mm 11 Pull gently...

Page 128: ...ure Location of motor axis 1 on page 122 17 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 159 18 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may...

Page 129: ...of motor axis 2 Location of motor axis 2 The motor axis 2 is located on the left hand side of the robot as shown in the figure below xx0200000470 A Attachment screws cover 5 pcs B Cover C Connection box D Gasket E Motor axis 2 F Attachment screws motor 4 pcs G O ring H Correct orientation of holes on top of motor Continues on next page ...

Page 130: ...e brakes Standard toolkit The content is defined in section Standard toolkit on page 178 Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit Diagram See chapter Circuit diagram Ac...

Page 131: ... the lower arm will be movable and may fall down Secure the robot arms before unscrewing any of the attachment screws of the axis 2 motor xx0700000660 7 WARNING Oil will be running out of the motor attachment hole when removing the motor It may also be hot Take any necessary measures to collect the oil 8 Unscrew the four attachment screws and washers of the motor Shown in the figure Location of mo...

Page 132: ...or See the figure below Art no is specified in Required equipment on page 128 8 Rotate the motor shaft several turns using the measuring tool There must always be some backlash meaning that the shaft should go easy to rotate 9 Place the tip of a dial indicator against the scribed mark on the measuring tool The tip of the dial indicator must measure on a 50 mm radius from the center of the motor sh...

Page 133: ...igure Location of motor axis 2 on page 127 17 Reconnect connectors R3 MP2 and R3 FB2 xx0200000401 A R3 MP2 B R3 FB2 C Connection box 18 Refit the cover of the connection box Shown in the figure Location of motor axis 2 on page 127 19 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in sect...

Page 134: ... right hand side of the robot as shown in the figure below A more detailed view of the component and its position may be found in chapter Spare parts and exploded views on page 181 in part 2 of the Product manual xx0200000471 A Attachment screws cover B Cover C Connection box D Gasket E Motor axis 2 F Attachment screws motor 4 pcs G O ring H Correct orientation of holes on top of motor Continues o...

Page 135: ...tandard toolkit The content is defined in section Standard toolkit on page 178 Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit Diagram See chapter Circuit diagram Action Note ...

Page 136: ...ing the holding brakes of the motor the upper arm will be movable and may fall down Secure the upper arm before loosening any of the screws on the motor xx0700000660 7 WARNING Oil will be running out of the motor attachment hole when removing the motor It may also be hot Take any necessary measures to collect the oil 8 Unscrew the four attachment screws and plain washers of the motor Shown in the ...

Page 137: ...ipment on page 133 8 Rotate the motor shaft several turns using the measuring tool There must always be some backlash meaning that the shaft should go easy to rotate See the figure below 9 Place the tip of a dial indicator against the scribed mark on the measuring tool The tip of the dial indicator must measure on a 50 mm radius from the center of the motor shaft xx0200000473 A Measuring tool 10 S...

Page 138: ...tion of motor axis 3 on page 132 17 Reconnect the motor connectors R3 MP3 and R3 FB3 xx0200000401 A R3 MP3 B R3 FB3 C Connection box 18 Refit the cover of the connection box Shown in the figure Location of motor axis 3 on page 132 19 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in sect...

Page 139: ...found in chapter Foldouts in the Product manual reference information xx0200000476 Required equipment Note The different motors are not compatible Make sure to replace with correct model A Torx screw B Cover C Connection box D Screw E Motor 6 F Motor 5 G Motor 4 H Gearbox Equipment etc Spare part no Art no Note Motor unit axis 4 3HAC11864 1 Elmo Motor unit axis 4 3HAC021740 001 Yaskawa Motor unit ...

Page 140: ...ent etc Spare part no Art no Note Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Remove the cover of the connection box Shown in the figure Location of motors axes 4 6 on page 137 3 Loosen connectors R3 MP5 6 and R3 FB5 6 xx0300000063 4 Remove the connection box by unscrewing its three attachment screws and plain washers 5 Use...

Page 141: ...isconnect the connectors R3 MP4 and R3 FB4 5 Remove the connection box by unscrewing its three attachment screws and plain washers 6 Use a marker pen to mark out the position of the motor 7 Remove the motor by unscrewing its attachment screws and plain washers 8 Remove the motor by gently lifting it straight out horizontal movement Action Note Illustration 1 DANGER Turn off all electric power hydr...

Page 142: ...ents to avoid noticing the magnetic field which makes the gears stick together 9 Push or tap the motor in radial direction so that the play becomes minimal within one motor turn without the gear chewing Do not use force 10 Tighten the motor attachment screws and secure them with locking fluid 4 1 Nm Loctite 243 11 Perform a leak down test Detailed in section Performing a leak down test on page 76 ...

Page 143: ...t no is specified in Required equipment on page 137 5 The motor s fixing screws shall be fastened but do not tighten them to ensure that the motor will be able to move parallel to the gear when the adjustment is done 6 In order to release the brakes connect the 24 VDC power supply to the motor Connector to connector R3 MP5 pin 7 pin 8 7 Locate the smallest play by turning the outgoing shaft for ax...

Page 144: ...ANGER First test run may cause injury or damage on page 35 Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Check that the assembly surfaces are clean and the motor unscratched 3 Fit an new o ring on the motor Spare part no is specified in Required equipment on page 137 4 Fit the measuring tool at the rear of the motor Look at th...

Page 145: ...ing the magnetic field which makes the gears stick together 8 Push or tap the motor in radial direction so that the play becomes minimal within one motor turn without the gear chewing Do not use force 9 Tighten the motor attachment screws and secure them with locking fluid Tightening torque 4 1 Nm Loctite 243 10 Reconnect the cabling Described in Refitting cable harness axes 4 6 on page 91 11 Reca...

Page 146: ...ke sure to replace with correct model A Torx screw B Cover C Connection box D Screw E Motor axis 6 F Motor axis 5 G Motor axis 4 H Gearbox Equipment etc Spare part no Art no Note Motor unit axis 4 3HAC10602 1 Elmo Motor unit axis 4 3HAC021353 001 Yaskawa Motor unit axis 5 3HAC10600 1 IRB 2400 10 Elmo Motor unit axis 5 3HAC10601 1 IRB 2400 16 Elmo Motor unit axis 5 3HAC021722 001 IRB 2400 10 16 Yas...

Page 147: ... may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Drain the oil from the axis 4 gearbox 3 Remove the cover of the connection box Shown in the ...

Page 148: ...l movement Action Note Illustration Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Check that the assembly surfaces are clean and the motor unscratched 3 Fit a new o ring on the motor Spare part no is specified in Required equipment on page 144 4 Lubricate the gear with bearing grease Art no is specified in Required equipment ...

Page 149: ...r attachment screws and secure them with locking fluid Tightening torque 4 1 Nm Loctite 243 11 Refill the gearbox with oil Art no and amount is specified in Required equipment on page 144 12 Reconnect the cabling Described in Refitting cable harness axes 4 6 on page 91 13 Recalibrate the robot When all service work is done i e the other motors are also refitted Calibration is detailed in a separat...

Page 150: ...allest Turn the motor for axis 5 one full turn at a time for a total of five turns Find where the smallest play is within this area Use swift movements to avoid noticing the magnetic field which makes the gears stick together 8 Push or tap the motor in radial direction so that the play becomes minimal within one motor turn without the gear chewing Do not use force 9 Tighten the motor attachment sc...

Page 151: ...the adjustment is done 6 In order to release the brakes connect the 24 VDC power supply to the motor Connect to connector R3 MP6 pin 7 pin 8 7 Find the smallest play by turning the outgoing shaft for axis 4 in intervals of 90 one full turn and thereby finding the area where the play for motor 6 becomes smallest Turn the motor for axis 5 one full turn at the time totally five turns Find the smalles...

Page 152: ...s are also refitted Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 159 12 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 35 Action Note...

Page 153: ...s position may be found in chapter Spare parts and exploded views on page 181 in part 2 of the Product manual Note The gearbox is not normally serviced or adjusted xx0300000007 Required equipment A Attachment screws gearbox unit B Bottom plate Equipment Spare part no Art no Note Gearbox axes 1 3 3HAC025711 001 Standard toolkit The content is defined in section Standard toolkit on page 178 Calibrat...

Page 154: ...e motor axis 1 Detailed in section Removal motor axis 1 on page 123 5 Remove the motor axis 2 Detailed in section Removal motor axis 2 on page 128 6 Remove the motor axis 3 Detailed in section Removal motor axis 3 on page 133 7 CAUTION The complete gearbox unit weighs 200 kg without the base All lifting equipment used must be sized accordingly 8 Place the remaining parts of the robot upside down o...

Page 155: ... page 124 8 Refit the motor axis 2 Detailed in section Refitting motor axis 2 on page 129 9 Refit the motor axis 3 Detailed in section Refitting motor axis 3 on page 134 10 Refit the complete lower arm Detailed in section Refitting lower arm on page 109 11 Refit the cable unit axes 1 3 Detailed in section Refitting gearbox axis 1 3 on page 152 12 Calibrate the robot Calibration is detailed in a se...

Page 156: ... shown in the figure below xx0300000012 Required equipment Equipment etc Spare part no Art no Note Drive shaft unit axes 5 6 3HAC11804 1 Gear belt 3HAA2393 1 2 pcs Adjustment tool 3HAA7601 50 Lifting device robot Standard toolkit The content is defined in section Standard toolkit on page 178 Other tools and procedures may be required See references to these procedures in the step by step instructi...

Page 157: ...n Removal wrist unit on page 100 3 Loosen the connection box and disconnect the connectors on the motors of axes 5 and 6 Mark the motor number on the motors to simplify the reconnecting Detailed in section Replacement of motors axes 4 6 IRB 2400L on page 137 4 Undo the screws xx0300000021 A Screws B Motor screws 5 Squeeze the drive shafts together at the tip of the tubular shaft so they can pass t...

Page 158: ...Place the round post of the adjustment tool into the motor pulley and let the cam press to the outer diameter of the large pulley Art no is specified in Required equipment on page 154 Tighten screws B shown in the illustration below to 4 1 Nm 6 Rotate the drive shafts Check the tension on the belt 7 Install the drive mechanism in the tubular shaft Do not forget the rubber damper 8 Tighten screws x...

Page 159: ...1 Revision C Copyright 2004 2008 ABB All rights reserved 12 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 35 Action Note Illustration Continued ...

Page 161: ...obot has Absolute Accuracy calibration it is also recommended but not always needed to be calibrated for new Absolute Accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot for example motors or parts of transmission Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost the counters mus...

Page 162: ...ion Pendulum standard method or Levelmeter calibration alternative method Absolute Accuracy calibration optional Based on standard calibration and besides positioning the robot at home position the Absolute Accuracy calibration also compensates for mechanical tolerances in the robot structure deflection due to load Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coor...

Page 163: ...ical tolerances to the toolkit parts as the standard method with Calibration Pendulum This method may after calibration require modifications in the robot program and is therefore not recommended The calibration equipment for Levelmeter Calibration is ordered as separate parts for each robot and the operating manual for Levelmeter Calibration is enclosed with the Levelmeter 2000 CalibWare Absolute...

Page 164: ...2004 2008 ABB All rights reserved 5 3 Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and or correct axis position for all robot models Calibration scales IRB 2400 The illustration below shows the calibration marks on all axes of the robot en0200000273 ...

Page 165: ...ards the calibration position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software Calibration movement directions 6 axes Note The figure shows an IRB 7600 but the positive direction is the same for all 6 axis robots except the positive direction of axis 3...

Page 166: ...details the second step when updating the revolution counter storing the revolution counter setting with the TPU RobotWare 4 0 Action Note 1 Select axis by axis motion mode 2 Jog the robot to place the calibration marks within the tolerance zone IRB 140 1400 2400 4400 6600ID 6650ID 6640ID Axes 5 and 6 must be positioned together Shown in section Calibration scales and correct axis position on page...

Page 167: ...te from the Calib menu The Revolution Counter Update window appears xx0100000202 4 Select the desired axis and press Incl to include it it will be marked with an x or press All to select all axes 5 Press OK when all axes that are to be updated are marked with an x CANCEL returns to the Calibration window 6 Press OK again to confirm and start the update CANCEL returns to the Revolution Counter Upda...

Page 168: ...he calibration position very carefully after each update How to perform the check is detailed in section Checking the calibration position on page 168 Action Note Action 1 On the ABB menu tap Calibration All mechanical units connected to the system are shown along with their calibration status 2 Tap the mechanical unit in question A screen is displayed tap Rev Counters en0400000771 3 Tap Update Re...

Page 169: ...updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the ticked revolution counters and removes the tick from the list of axes 6 CAUTION If a revolution counter is incorrectly updated it will cause incorrect robot positioning which in turn may cause damage or injury Check the cal...

Page 170: ...J 0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E9 NoEOffs v1000 z50 Tool0 4 Run the program in manual mode 5 Check that the calibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 162 How to update the revolution counters is detailed in section Updating revolution counters on pa...

Page 171: ...arks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 162 Detailed in section Updating revolution counters on page 164 Action Note 1 Tap Jogging in the ABB menu 2 Tap Motion mode to choose group of axes to jog 3 Tap axis 1 3 to jog axis 1 2 or 3 4 Manually run the robots axes t...

Page 173: ...3HAC022031 001 Revision C Copyright 2004 2008 ABB All rights reserved 6 Reference information 6 1 Introduction General This chapter includes general information complementing the more specific information in the different procedures in the manual ...

Page 174: ...mation systems safety of integrated manufacturing systems Basic requirements prEN 999 Safety of machinery The positioning of protective equipment in respect of approach speeds of the human body Standards robot cell The following standards are applicable when the robot is part of a robot cell EN 294 Safety of machinery Safety distance to prevent danger zones being reached by the upper limbs EN 349 ...

Page 175: ...04 2008 ABB All rights reserved 6 3 Unit conversion Converter table Use the table below to convert units used in this manual Quantity Units Length 1 m 3 28 ft 39 37 in Weight 1 kg 2 21 lb Pressure 1 bar 100 kPa 14 5 psi Force 1 N 0 738 lbf Moment 1 Nm 0 738 lbf tn Volume 1 L 0 264 US gal ...

Page 176: ...mo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screws lubricated in other ways Screws lubricated with Molycote ...

Page 177: ...Maximum allowed total deviation from the specified value is 10 The table below specifies the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws The table below specifies the recommended standard tightening torque for oil lubricated screws with Allen head screws The table below specifies the recommended standard tightening torque for Molycote l...

Page 178: ...rque for water and air connectors when one or both connectors are made of brass M16 235 280 M24 790 950 Dimension Tightening torque Nm Nominal Tightening torque Nm Min Tightening torque Nm Max 1 8 12 8 15 1 4 15 10 20 3 8 20 15 25 1 2 40 30 50 3 4 70 55 90 Dimension Tightening torque Nm Class 10 9 Molycote lubricated Tightening torque Nm Class 12 9 Molycote lubricated Continued ...

Page 179: ...cified All components exceeding 22 kg 50 lbs are high lighted in this way To avoid injury ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg A wide range of lifting tools and devices are available for each manipulator model Example Below is an example of how a weight specification is presented inside a procedure table Action Note CAUTION The motor we...

Page 180: ...ndard are gathered in the Standard toolkit and defined in the table below This way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents standard toolkit Qty Tool 1 Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Torque wrench 10 100 Nm 1 Small screwdriver 1 Plastic mallet 1 Ratchet head for torque wrench 1 2 1 KM...

Page 181: ...lternative method Levelmeter Calibration Calibration equipment Calibration Pendulum The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method Description Art no Note Guide pins M8 length 70 mm Used for guiding the wrist into place Measuring tool 3HAB7887 1 Used for measuring the gear play when refitting the motors Dismounting tool sh...

Page 182: ...General Many repair and maintenance activities require different pieces of lifting equipment which are specified in each procedure The use of each piece of lifting equipment is not detailed in the activity procedure but in the instruction delivered with each piece of lifting equipment This implies that the instructions delivered with the lifting equipment should be stored for later reference ...

Page 183: ...ws 7 1 Introduction 181 3HAC022031 001 Revision C Copyright 2004 2008 ABB All rights reserved 7 Spare parts and exploded views 7 1 Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot ...

Page 184: ...n section Replacement of motor axis 1 on page 122 3HAC4789 1 IRB 2400 L 10 16 Elmo 3HAC14271 1 IRB 2400 Wall mounted Elmo 3HAC021346 001 IRB 2400 L 10 16 Yaskawa 3HAC021961 001 IRB 2400 Wall mounted Yaskawa 5 1 Motor axis 1 Recommended spare part 3HAC031021 001 Cleanroom L 10 16 Yaskawa 5 1 Motor axis 3 Recommended spare part Replacement is detailed in section Replacement of motor axis 3 on page 1...

Page 186: ...0L 15 1 Damper axis 3 3HAB 5512 1 16 4 Torx pan head roll screw 9ADA 629 56 M6x16 18 1 Parallel arm 3HAB 9394 1 26 2 Hex socket head cap screw 9ADA 183 34 M8x12 32 1 Sealing 3HAC 10089 2 33 1 Locking washer 3HAB 5523 1 SS 1914 04 34 1 Hex socket counters head 2121 2852 449 M8x16 8 8 35 1 Sealing 3HAC 10088 4 Acetal POM 41 14 700 ml Lubricating oil 11712016 604 Also shown in Foldout 1 43 1 ml Locki...

Page 187: ...ll bearing 3HAB3643 12 61822 2RS1 21 2 Sealing ring 3HAB5515 1 Acetal 36 1 Motor axis 2 Recommended spare part Replacement is detailed in section Replacement of motor axis 2 on page 127 3HAC4790 1 Elmo 3HAC021350 001 Yaskawa 36 1 Motor axis 2 Recommended spare part 3HAC031022 001 Cleanroom L 10 16 Yaskawa 41 14 700 ml Lubricating oil 11712016 604 Also shown in Foldout 1 42 1 g Bearing grease 3HAB3...

Page 188: ...in Foldout 4 5 119 12 Cable straps outdoor 2166 2055 3 L 208 mm 132 2 Dust cap 3HAC7561 3 133 1 Dust cap 3HAC 7561 4 135 3 Hex socket head pan screw 9ADA 183 34 M8x12 8 8 137 63 Torx pan head roll screw 9ADA629 44 M5x12 Also in Foldout 4 5 Also shown in Foldout 3 5 139 1 Coupling 3HAB 3333 20 140 Locking liquid 1269 0014 412 Loctite 542 141 2 Protective hood 2522 2101 8 D 11 4 13 147 3 Gasket moto...

Page 189: ...61 3 136 8 Torx pan head roll screw 9ADA629 34 M4x12 Ext conn 137 63 Torx pan head roll screw 9ADA629 44 M5x12 Also in Foldout 4 5 Also shown in Foldout 3 5 147 3 Gasket motor axes 1 3 3HAC4419 1 Also shown in Foldout 3 150 Flange sealing 12340011 116 Loctite 574 Also shown in Foldout 4 157 1 Adaptor customer cabling 3HAB7328 1 Also shown in Foldout 3 157 1 Cover protection 3HAC6823 1 158 1 Adapto...

Page 190: ... is therefor the total quantity of the article used for the complete robot For more specified information about exact quantity see the chapter Repair and the replacement procedure for the part involved 137 63 Torx pan head roll screw 9ADA629 44 M5x12 Also in Foldout 4 5 Also shown in Foldout 3 5 138 6 Cable straps outdoors 21662055 1 L 101 mm 151 Adhesive tape 11699198 301 19x0 18 152 1 Bracket 3H...

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Page 196: ...sher 9ADA312 7 8 4x16x1 6 25 1 Motor unit axis 5 Recommended spare part Replacement is detailed in section Replacement of motors axes 4 6 IRB 2400 10 16 on page 144 3HAC10600 1 IRB 2400 10 Elmo 3HAC10601 1 IRB 2400 16 Elmo 3HAC021722 001 IRB 2400 10 16 Yaskawa 25 1 Motor unit axis 5 Recommended spare part 3HAC031024 001 Cleanroom Yaskawa 26 1 Motor unit axis 4 Recommended spare part Replacement is...

Page 197: ... 51 6 ml Locking liquid 3HAB7116 1 Loctite 243 52 3 Gasket motor axes 4 6 3HAC4429 1 53 1 Cable unit axes 4 6 3HAC9328 1 Recommended spare part Replacement is detailed in section Replacement of cable harness axes 4 6 on page 87 54 9 Torx pan head screw 9ADA618 46 M5x20 8 8 55 9 Cable straps outdoor 21662055 1 2 5x101 56 Adhesive tape 11699198 301 500 mm 19x0 18 57 1 Cover 3HAB6491 1 58 1 Cover wit...

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Page 200: ... 10 Plain washer 9ADA312 6 6 4x12x1 6 A2F 14 4 Hex socket head cap screw 3HAB3402 30 M6x45 8 8 Gleitmo 610 15 1 Drive unit axis 5 6 See section Spare parts drive unit IRB 2400 L on page 193 16 1 Motor unit axis 4 3HAC11864 1 Elmo 3HAC021740 001 Yaskawa 16 1 Motor unit axis 4t 3HAC031019 001 Cleanroom Yaskawa 17 4 Hex socket head cap screw 9ADA183 14 M5x16 8 8 A2F 18 1 O ring 21522011 414 44 2x3 Ni...

Page 201: ... axes 5 6 3HAB 3230 1 49 2 Torx pan head roll screw 9ADA 629 47 M5x25 8 A2F 50 1 Parallel bar 3HAC 1563 1 51 1 Damper axis 3 3HAB 5511 1 52 2 Hex socket head cap screw 9ADA 183 22 M6x10 8 8 A2F 53 2 Spherical roller bearing 3HAA 2167 12 D 30 62 W 20 22206 CC Standard 54 2 Sealing 3HAC 10088 4 55 1 Sealing 3HAC 10089 2 56 1 Locking washer 3HAA 2356 11 9x35x3 57 1 Hex socket head cap screw 3HAB 3402...

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Page 204: ...ement is detailed in section Replacement of drive shaft unit IRB 2400L on page 154 2 2 Motor unit axes 5 6 Recommended spare part Replacement is detailed in section Replacement of motors axes 4 6 IRB 2400L on page 137 3HAC11865 1 Elmo 3HAC021741 001 Yaskawa 2 2 Motor unit axis 5 6 Recommended spare part 3HAC031020 001 Cleanroom Yaskawa 3 1 Motor plate 3HAA2504 1 4 8 Hexagon nut 9ADA267 5 M5 8 A2F ...

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Page 206: ...t 2004 2008 ABB All rights reserved 7 7 Spare parts customer cable axis 4 Customer cable axis 4 spare part list The spare part of the customer cable axis 4 is listed below and shown in the following figure xx0300000409 Qty Description Spare part no Note 1 Customer cable extension axis 4 3HAC 8869 1 Option 043 ...

Page 207: ...w button head 3HAC 0596 31 M8x12 3 7 Cam blank 3HAB 8086 1 4 24 Torx pan head screw 9ADA 618 55 M6x12 5 1 Attachment plate 3HAC 0982 1 6 2 Torx pan head screw 9ADA 618 56 M6x16 7 0 Position switch 1 3HAC 6447 1 1 Position switch 1 3 3HAC 6448 1 8 6 Hex socket head cap screw 9ADA 183 5 M4x16 9 9 Shims sheet 3HAB 7478 1 10 4 Torx pan head roll screw 9ADA 629 42 M5x8 11 6 Clamp 2166 2018 9 D 8 12 1 C...

Page 209: ...am 8 1 Introduction 197 3HAC022031 001 Revision C Copyright 2004 2008 ABB All rights reserved 8 Circuit diagram 8 1 Introduction Overview This chapter includes the circuit diagram for the robot Continues on next page ...

Page 211: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 101 LIST OF CONTENTS ...

Page 212: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 102 CONNECTION POINT LOCATIONS ...

Page 213: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 103 BRAKE UNIT SERIAL MEASUREMENT BOARD ...

Page 214: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 104 MOTOR AXIS 1 3 ...

Page 215: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 105 BRAKE UNIT SERIAL MEASUREMENT BOARD ...

Page 216: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 106 MOTOR AXIS 4 6 1 5 10 16 ...

Page 217: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 107 FEED BACK AXIS 4 6 1 5 10 16 ...

Page 218: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 108 MOTOR AXIS 4 6 1 8 5 ...

Page 219: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 109 FEED BACK AXIS 4 6 1 8 5 ...

Page 220: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 110 CUSTOMER CONNECTIONS ...

Page 221: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 111 INTEGRATED WIREFEED CABLING OPTION ...

Page 222: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 112 POS INDICATOR AXIS 1 OPTION ...

Page 223: ...Manipulator Circuit Diagram 3HAC 6670 3 Rev 01 Product Manual IRB 2400 No of Sheets 13 Sheet no 113 EXTERNAL CONNECTIONS OPTIONS ...

Page 224: ...ad 40 ESD damage elimination 36 sensitive equipment 36 explanation safety symbols 32 F figures connectors on robot 60 FlexPendant jogging to calibration position 169 MoveAbsJ instruction 168 updating revolution counters 166 forces and torques on robot 40 foundation 40 attachment screws 47 orienting and securing robot 47 requirements 41 G gearbox axes 1 3 replacing 151 guide sleeves securing robot ...

Page 225: ...ors 60 orienting and securing 47 robot position 162 S safety equipment mechanical stop axis 1 52 mechanical stop axis 2 57 position switch axis 3 59 Safety service 16 safety symbols 32 scales on robot 162 schedule for maintenance 67 signal connectors 60 SMB battery replacing 72 SMB unit replacing 114 special tools 179 storage conditions 41 symbols safety 32 sync marks 162 T testing brakes 27 tie r...

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Page 227: ...ABB AB Robotics Products S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 3HAC 022031 001 Revision C en ...

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