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

Product manual, procedures
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, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without ABBs written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this manual may be obtained from ABB at its then current charge.
Copyright 2004 ABB All right reserved. ABB Automation Technologies AB Robotics SE-721 68 Vsters Sweden
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 0.0.2 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 manipulators 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 manipulators working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 1.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 2: Installation and commissioning 33
2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

2.1: Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.1.1 Pre-installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 2.1.2 Working range, IRB 4400/45 and /60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 2.1.3 Working range, IRB 4400/L30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 2.1.4 Working range, IRB 4400/L10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 2.1.5 Working range, IRB 4400/S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
2.2: On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
2.2.1 Lifting manipulator with round slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 2.2.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 2.2.3 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 2.2.4 Fitting equipment on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 2.2.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
2.3: Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
2.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 2.3.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 2.3.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 2.3.4 Electrically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 2.3.5 Unlimited working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
2.4: Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
2.4.1 Customer connection on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 2.4.2 Customer connections on upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
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3: Maintenance
71
3.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.1: Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.1.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 3.1.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.2: General maintenance activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.2.1 Inspection of mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 3.2.2 Replacement of battery pack, measuring system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 3.2.3 Cleaning of manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.3: Change and checking of oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.3.1 Oil in gearbox unit, axis 1-2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 3.3.2 Inspection of oil levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 3.3.3 Oil change, gearbox axis 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 3.3.4 Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10) . . . . . . . . . . . . . 86 3.3.5 Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 4: Repair 93 4.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.1: General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.1.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 4.1.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 4.1.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2: Complete robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2.1 Removal of cable harness, axes 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 4.2.2 Refitting of cable harness, axes 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 4.2.3 Removal of cable harness, axes 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 4.2.4 Refitting of cable harness, axes 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 4.2.5 Removal of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 4.2.6 Refitting of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.3: Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.3.1 Removal of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 4.3.2 Refitting of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 4.3.3 Removal of wrist unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 4.3.4 Refitting of wrist unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 4.3.5 Replacement of arm house unit, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 4.3.6 Replacement of mechanical stop, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 4.3.7 Replacement of signal cabling, upper arm (option 042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 4.3.8 Measuring the play, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 4.3.9 Measuring the play, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.4: Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.4.1 Removal of lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 4.4.2 Refitting of lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 4.4.3 Removal of tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 4.4.4 Refitting of tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 4.4.5 Removal of parallel arm /Removal of bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 4.4.6 Refitting of parallel arm /Refitting of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.5: Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.5.1 Removal of balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 4.5.2 Refitting of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 4.5.3 Replacement of serial measurement unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 4.5.4 Replacement of pushbutton unit for brake release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 4.5.5 Replacement of mechanical stop pin, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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4.6: Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
4.6.1 Removal of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180 4.6.2 Refitting of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182 4.6.3 Removal of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186 4.6.4 Refitting of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188 4.6.5 Removal of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 4.6.6 Refitting of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193 4.6.7 Adjustment of motors, axes 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196 4.6.8 Removal of motor, axes 4, 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198 4.6.9 Refitting of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 4.6.10 Refitting of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203 4.6.11 Refitting of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
4.7: Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
4.7.1 Removal of gearbox unit, axes 1-2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209 4.7.2 Refitting of gearbox unit, axes 1-2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212 4.7.3 Adjusting play on axis 4, intermediate gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216 5: Calibration 219
5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219

5.1: Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
5.1.1 How to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220 5.1.2 Calibration, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
5.2: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
5.2.1 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222 5.2.2 Directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 5.2.3 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 5.2.4 Positions and directions of sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226 5.2.5 Initialization of Levelmeter 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
5.3: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
5.3.1 Fine calibration procedure on TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 5.3.2 Resetting of Levelmeter 2000 and sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233 5.3.3 Calibration, axis 1, IRB 4400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236 5.3.4 Calibration, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238 5.3.5 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 6: Calibration, M2004 251
6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
3HAC 022032-001
Table of Contents
3HAC 022032-001
0.0.1 Overview
0.0.1 Overview
About this manual
This manual contains instructions for

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

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

installation personnel maintenance personnel repair personnel.
Prerequisites
The reader should...

be a trained maintenance/repair craftsman have the required knowledge of mechanical and electrical installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter
Safety, service Installation and commissioning Maintenance Repair Calibration
Contents
Safety information Information about installation of the manipulator. Information about maintenance work, including maintenance schedules. Information about repair work. Information about calibration of the manipulator.
References Reference Document Id
3HAC 022032-001
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0.0.1 Overview
Revisions Revision
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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.
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3HAC 022032-001
0.0.2 Reading the product manual
General
Information in the Product manual is written with specific principles. This section describes some of the principles.
Reading the instructions
The instructions contain references to figures, tools, material etc. The references are read as described below.
References to figures
The instructions often include references to components or attachment points located on the manipulator. The components or attachment points are marked with italic text in the instructions and completed with a reference to the figure where the current component or attachment point is shown. The denomination in the instruction for the component or attachment point corresponds to the denomination in the referenced figure. The table below shows an example of a reference to a figure from a step in an instruction.
Step
8.
Action
Note/Illustration
Remove the rear attachment screws, gearbox. Shown in the figure Location of gearbox .
References to required equipment
The instructions often include references to equipment (spare parts, tools etc.) required for the different actions in the instruction. The equipment is marked with italic text in the instructions 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.
Step
3.
Action
Fit a new sealing, axis 2 to the gearbox.
Note/Illustration
Art. no. is specified in Required equipment .
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Danger levels
The table below defines the captions specifying the danger levels used thoughout this manual.
Symbol
Designation
DANGER
Signification
Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc. 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 voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc. Warns that an accident may occur if the instructions are not followed, that can result in injury and or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown. Note symbols alert you to important facts and conditions.
danger
WARNING
warning
CAUTION
caution
NOTE
Note
TIP
Tip symbols advice you to specific instructions, where to find additional information or how to perform a certain operation in an easier way. The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personnel injury or death.
Tip
ELECTRICAL SHOCK
Electrical shock
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0.0.3 Product documentation, M2000
General
The complete product documentation kit for the M2000 robot system, including controller, manipulator and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, manipulators and controller cabinets, will be delivered with a Product manual that is divided into two parts: Product manual, procedures
Safety information Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software) Maintenance (descriptions of all required preventive maintenance procedures including periodicity) Repair (descriptions of all recommended repair procedures including spare parts) Additional procedures, if any (calibration, decommissioning).
Product manual, reference information

Reference information (article numbers for documentation refered to in Product manual, procedures, lists of tools, safety standards) Part list Foldouts or exploded views Circuit diagrams.
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for basic understanding of the operating system to manuals for entering parameters during operation. A complete listing of all available software manuals is available from ABB.
Hardware option manual
Each hardware option is supplied with its own documentation. Each document set contains the types of information specified below:
Installation information Repair information Maintenance information
In addition, spare part information is supplied for the entire option.
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General
The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any one delivery of robot products will not contain all documents listed, but only some of them. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems.
Hardware manuals
All hardware, manipulators and controller cabinets, will be delivered with a Product manual that is divided into two parts: Product manual, procedures
Safety information Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software) Maintenance (descriptions of all required preventive maintenance procedures including periodicity) Repair (descriptions of all recommended repair procedures including spare parts) Additional procedures, if any (calibration, decommissioning).
Product manual, reference information

Reference information (article numbers for documentation refered to in Product manual, procedures, lists of tools, safety standards) Part list Foldouts or exploded views Circuit diagrams.
RobotWare manuals
The following manuals describe the robot software in general and contain reference information about it:
RAPID Overview : An overview of the RAPID programming language. RAPID reference manual part 1 : Description of all RAPID instructions. RAPID reference manual part 2 : Description of all RAPID functions and data types. Technical reference manual - System parameters : Description of system parameters and configuration workflows.
Application manuals
Specific applications (e.g. software or hardware options) are described in Application manuals . An application manual can describe one or several applications. An application manual generally contains information about:
The purpose of the application (what does it do and when is it useful) What is included (e.g. cables, I/O boards, RAPID instructions, system parameters) How to use the application Examples of how to use the application
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Operating Manuals
This group of manuals is aimed at those having first hand operational contact with the robot, 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)
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1 Safety, service
1.0.1 Introduction
1: Safety, service
1.0.1 Introduction
Definitions
This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.
Sections
The chapter "Safety, service" is divided into the following sections: 1. General information contains lists of:
Safety, service -general Limitation of liability Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories:
Safety risks related to gripper/end effector Safety risks related to tools/workpieces Safety risks related to pneumatic/hydraulic systems Safety risks during operational disturbances Safety risks during installation and service Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions Fire extinguishing Emergency release of the manipulators arm Brake testing Risk of disabling function "Reduced speed 250 mm/s" Safe use of the Teach Pendant Unit enabling device Work inside the manipulators working range Signal lamp (optional)
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1 Safety, service
1.1.1 Safety, service - General
1.1: General information 1.1.1 Safety, service - General
Validity and responsibility
The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed. The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly. Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. Users Guide and Product Manual.
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
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1 Safety, service
1.1.2 Limitation of Liability
1.1.2 Limitation of Liability
General
Any information given in this information product regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions have been complied with.
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1 Safety, service
1.1.3 Related information
1.1.3 Related information
General
The list below specifies documents which contain useful information:
Documents Type of information

Installation of safety devices Changing robot modes
Detailed in document
Product manual for the manipulator Users Guide
Section
Installation and commissioning Start-up Installation and commissioning
Restricting the working space Product manual for the manipulator
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1 Safety, service
1.2.1 Safety risks related to gripper
1.2: Safety risks 1.2.1 Safety risks related to gripper

Ensure that a gripper is prevented from dropping a workpiece, if such is used.
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1 Safety, service
1.2.2 Safety risks related to tools/workpieces
1.2.2 Safety risks related to tools/workpieces
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller.
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1 Safety, service
1.2.3 Safety risks related to pneumatic/hydraulic systems
1.2.3 Safety risks related to pneumatic/hydraulic systems
General
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy
Residual energy may be present in these systems so, after shutdown, particular care must be taken. The pressure in pneumatic and hydraulic systems must be released before starting to repair them.
Safe design
Gravity may cause any parts or objects held by these systems to drop. Dump valves should be used in case of emergency. Shot bolts should be used to prevent tools, etc., from falling due to gravity.
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1 Safety, service
1.2.4 Safety risks during operational disturbances
1.2.4 Safety risks during operational disturbances
General
The industrial robot is a flexible tool which can be used in many different industrial applications. All work must be carried out professionally and in accordance with the applicable safety regulations. Care must be taken at all times.
Qualified personnel
Remedial action must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.
Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.
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1 Safety, service
1.2.5 Safety risks during installation and service
1.2.5 Safety risks during installation and service
General risks during installation and service
The instructions in the Product Manual - Installation and Commissioning must always be followed. Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. Those in charge of operations must make sure that safety instructions are available for the installation in question. Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it.
Nation/region specific regulations
To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.
Non-voltage related risks
Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices. Turntables or the like should be used to keep the operator out of the robot's working space. The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the parallel arm. Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, is dismantled. When dismantling/assembling mechanical units, watch out for falling objects. Be aware of stored heat energy in the controller. Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete system
The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function. The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
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1 Safety, service
1.2.6 Risks associated with live electric parts
1.2.6 Risks associated with live electric parts
Voltage related risks, general
Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units. The mains supply to the robot must be connected in such a way that it can be turned off outside the robots working space.
Voltage related risks, controller
A danger of high voltage is associated with the following parts:

Be aware of stored electrical energy (DC link) in the controller. Units inside the controller, e.g. I/O modules, can be supplied with power from an external source. The mains supply/mains switch The power unit The power supply unit for the computer system (230 VAC) The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!) The drive unit (700 VDC) The service outlets (115/230 VAC) The power supply unit for tools, or special power supply units for the machining process The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains. Additional connections
Voltage related risks, manipulator
A danger of high voltage is associated with the manipulator in:

The power supply for the motors (up to 800 VDC) The user connections for tools or other parts of the installation (max. 230 VAC, see Installation and Commissioning Manual)
Voltage related risks, tools, material handling devices, etc
Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged.
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1 Safety, service
1.3.1 Safety fence dimensions
1.3: Safety actions 1.3.1 Safety fence dimensions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see Product Specification - Description, Robot Motion). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator.
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1 Safety, service
1.3.2 Fire extinguishing
1.3.2 Fire extinguishing

Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator or controller)!
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1.3.3 Emergency release of the manipulators arm
1.3.3 Emergency release of the manipulators arm
Description
In an emergency situation, any of the manipulators axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit. How to release the brakes is detailed in section Manually releasing the brakes in the Product manual for the manipulator. The manipulator arm may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury!
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1 Safety, service
1.3.4 Brake testing
1.3.4 Brake testing
When to test
During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed below: 1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load). 2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller. 3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake function is adequate.
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1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"

Note! Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.
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1 Safety, service
1.3.6 Safe use of the Teach Pendant Unit
1.3.6 Safe use of the Teach Pendant Unit

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state. To ensure safe use of the Teach Pendant Unit, the following must be implemented: The enabling device must never be rendered inoperative in any way. During programming and testing, the enabling device must be released as soon as there is no need for the robot to move. The programmer must always bring the Teach Pendant Unit with him/her, when entering the robots working space. This is to prevent anyone else taking control over the robot without the programmer knowing.
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1.3.7 Work inside the manipulators working range
1.3.7 Work inside the manipulators working range

Warning! If work must be carried out within the robots work envelope, the following points must be observed: - The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel. - The robots speed is limited to max. 250 mm/s when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% full speedmay only be used by trained personnel who are aware of the risks that this entails. - Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell. - Test the motor brake on each axis, according to section Brake testing on page 28.
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1 Safety, service
1.3.8 Signal lamp (optional)
1.3.8 Signal lamp (optional)
Description
A signal lamp with an yellow fixed light can be mounted on the manipulator, as a safety device. The signal lamp is required on an UL/UR approved robot.
Function
The lamp is active in MOTORS ON mode.
Further information
Further information about the MOTORS ON/MOTORS OFF mode may be found in the chapter Description, Control System in the Product manual for the controller.
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2 Installation and commissioning

2.0.1 Introduction
2: Installation and commissioning

2.0.1 Introduction
General
This chapter contains information for installing the manipulator to the working site. More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), may be found in the Product Specification for the manipulator.
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2.1.1 Pre-installation procedure
2.1: Unpacking 2.1.1 Pre-installation procedure
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 prerequisites for installation
The check-list below details what must be observed before proceeding with the actual installation of the manipulator: 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 manipulator 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, manipulator
The table below shows the weights of the different models:
Manipulator model
IRB 4400/45 IRB 4400/60 IRB 4400/L10 IRB 4400/L30 IRB 4400/S
Weight
985 kg 1040 kg 1040 kg 1060 kg 1290 kg
L - Long arm S - Shelf mounted manipulator
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Loads on foundation, manipulator
The table below shows the various forces and torques working on the manipulator during different kinds of operation. Stress forces for the manipulator version IRB 4400/S are detailed separately in the following table. Note! These forces and torques are extreme values that are rarely encountered during operation. The values also never simultaneously reach their maximum! The rigidity of the foundation must be designed to minimize the affects of dynamic behaviour on the robot. For optimal performance, the frequency for the foundation bearing the robot must be higher than 30 Hz. TuneServo can be used to adapt robot tuning for a non-optimal foundation. Fxy and Mxy are vectors that can have any direction on the xy plane. The illustration below shows the directions of the stress forces.
Z
xx0300000254
Force
Force xy Force z Torque xy Torque z
Endurance load (in operation)

7500 N +9500 2000 N 14000 Nm 2000 Nm
Max. load (emergency stop)

9000 N +9500 3000 N 16000 Nm 4000 Nm
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Loads on foundation, manipulator IRB 4400/S
0-30
30
X Z Z
X
xx0300000255
Force
Force x Force y Force z Torque x Torque y Torque z Force x' Force y' Force z' Torque x' Torque y' Torque z'
Endurance load (in operation)

5000 N 6000 10 000 5000 N 8500 Nm 3500 14 000 Nm 6500 Nm 5000 5000 N 6000 N 8500 3000N 9500 Nm 3500 7500 Nm 2000 Nm
Max. load (emergency stop)

7000 N 9000 N 10 000 7000 N 11 500 Nm 3500 11 500 Nm 11 000 Nm 5000 7000 N 9000 N 8500 5500 N 12 000 Nm 3500 11 500 Nm 5500 Nm
Storage conditions, manipulator
The table below shows the allowed storage conditions for the manipulator:
Parameter
Min. ambient temperature Max. ambient temperature Max. ambient temperature (less than 24 hrs) Max. ambient humidity
Value
-25C +55C +70C 95% at constant temperature
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Operating conditions, manipulator
The table below shows the allowed operating conditions for the manipulator:
Parameter
Min. ambient temperature Max. ambient temperature Max. ambient humidity
Value
+5C +45C 95% at constant temperature
Protection classes
The table below shows the protection class of the manipulator:
Manipulator
Standard version Foundry version
Protection class
IP54 IP67, steam washable
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2.1.2 Working range, IRB 4400/45 and /60
2.1.2 Working range, IRB 4400/45 and /60
Extreme positions
The illustration below shows the extreme positions of the robot arms IRB 4400/45 and /60:
53 R1
140 Pos 1
880
300 A-A
Pos 0
Pos 5
(6 0
kg
Pos 6
(45
kg
51
)
R4
0)
78
Pos 2
Pos 3
R
5 56
640 Pos 4
370
200 390 530
(1223) 1955
731
xx0300000241
Pos no.
0 1 2 3 4 5 6
Position X (mm)
1080 887 708 1894 570 51 227
Position Z (mm)
1720 2140 836 221 -126 1554 1210
Angle Axis 2 (degrees)

0 0 0 95 95 -70 -70

0 -30 65 -60 40 40 65
Robot motion
The table below specifies the types and ranges of the robot motion in every axis.
Location of motion
Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6
Type of motion
Rotation motion Arm motion Arm motion Wrist motion Bend motion Turn motion
Range of movement
+165to -165 +95to -70 +65to -60 +200to -200 +120to -120 +400to -400
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2.1.3 Working range, IRB 4400/L30
Extreme positions
The illustration below shows the extreme positions of the robot arm IRB 4400/L30:
C
53 R1
140
1380
300
A-A
(6
0k g
51
0)
E
5 56
18 4
F
370 390 (1453) 2432 978 200 530
640
xx0300000242
Positions in Position X illustration (mm)

B C D E F G H 1580 1320 919 2303 180 484 725
Position Z (mm)
1720 2390 383 -66 -448 1804 1254

0 0 0 95 95 -70 -70

0 -30 65 -60 42 40 65
Robot motion
Location of motion
Type of motion
Range of movement
+165to -165 +95to -70 +65to -60 +200to -200 +120to -120 +400to -400
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Extreme positions
The illustration below shows the extreme positions of the robot arm IRB 4400/L10:
C
85 A
1500
300
8.5 R9
A A-A
g 0k (6
0) 51
E
R 5 56
390
530 640
F
300 (1477) 2547 1070 200
xx0300000244
Position in Position X illustratio (mm) n

B C D E F G H 1700 1424 970 2401 500 588 845
Position Z (mm)
1720 2450 274 -135 -786 1864 1265

0 0 0 95 95 -70 -70

0 -30 65 -60 23.6 40 65
Robot motion
Location of motion
Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 40
Type of motion
Rotation motion Arm motion Arm motion Wrist motion Bend motion Turn motion Revision -
Range of movement
+165to -165 +95to -70 +65to -60 +200to -200 +120to -120 +400to -400 3HAC 022032-001

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

B C D E F G H 1580 1320 919 2360 239 484 725
Position Z (mm)
1720 2390 383 120 -417 1804 1254

0 0 0 90 90 -70 -70

0 -30 65 -60 44 40 65
Robot motion
The table below specifies the types and ranges of the robot motion in every axis. Location of motion
Type of motion
Range of movement
+135to -135 +90to -70 +65to -60 +200to -200 +120to -120 +400to -400
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2.2.1 Lifting manipulator with round slings
2.2: On-site installation 2.2.1 Lifting manipulator with round slings
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

Crane Round slings, 2 m
Art. no.
Note
Lifting capacity: 2100kg (max. load at 90) 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 Type: OBK 7-8
Lifting lugs
Warning! The manipulator weighs 1300 kg! All lifting equipment used must be dimensioned accordingly! 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.
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Lifting, manipulator version IRB 4400/45, /60, /L10, /L30
The lifting equipment is attached to the manipulator as shown in the figure below.
xx0300000245
A B
Angle (degrees specified for the different versions in the lifting instruction) Lifting lug
Lifting instruction, IRB 4400/45, /60, /L10, /L30
The procedure below details how to lift the complete manipulator (IRB 4400/45, /60, /L10, / L30).
Step
1.
Action
Info/Illustration
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. Move the manipulator to the calibration position.
2.
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Step
3.
Action
Move the lower arm backwards to get balance, according to angle specified to the right.
Info/Illustration
Angle (A) is shown in the figure Lifting, manipulator version IRB 4400/45, /60, / L10, /L30 on page 43. IRB 4400/45 and /L30: A: -5 IRB 4400/60 and /L10: A: 0
4.
Attach the round slings to the special eye Shown in the figure Lifting, manipulator bolts on the gearbox unit for axes 2 and version IRB 4400/45, /60, /L10, /L30 on 3 using lifting lugs . page 43. The roundsling and lifting lug dimensions must comply with the applicable standards specified in Required equipment on page 42. Lift the manipulator to its installation site. Make sure the slings do not rub against any sharp edges!
5.
Lifting manipulator version IRB 4400/S
The lifting equipment is attached to the manipulator as shown in the figure below.
(1)
(2)
30
x-x
xx0300000247
(1) (2) A B C
Lifting angle for the manipulator: 0 Lifting angle for the manipulator: 30 Angle (degrees specified for the different versions in the lifting instruction) Axis 2 Lifting lug
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Lifting instruction, IRB 4400/S
The procedure below details how to lift the complete manipulator (IRB 4400/S).
Step
1.
Action
Note/Illustration
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. Move the manipulator to the calibration position. 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 Attach the round slings to the special eye bolts on the gearbox unit for axes 2 and 3 using lifting lugs. If the lifting angle of the manipulator is more than 0, a round sling must also be attached to the rear of the robot. Lift the manipulator to its installation site. Make sure the slings do not rub against any sharp edges! Attachment points are shown in the figure Lifting manipulator version IRB 4400/ S on page 44. The roundsling and lifting lug dimensions must comply with the applicable standards specified in Required equipment on page 42.
2. 3.
4.
5.
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2.2.2 Manually releasing the brakes
General
The section below details how to release the holding brakes of each axis motor. This may be done in one of three ways:
using the pushbutton when the manipulator is connected to the controller. using the pushbutton on the manipulator with an external power supply. using an external voltage supply directly on the respective brake.
Danger! When releasing the holding brakes, the manipulator axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the manipulator arm!
Using the pushbutton when the manipulator is connected to the controller
The procedure below details how to release the holding brakes with pushbuttons, when the manipulator is connected to the controller.
Step
1.
Action
The internal brake release unit is located at the base of the manipulator.
Info/Illustration
R1.CP/CS
R1.MP
R1.SMB
xx0300000198
The brake release unit is equipped with six buttons for controlling the axes brakes. The buttons are numbered according to the numbers of the axes.
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Step
2.
Action
Release the holding brake on a particular axis by pressing the corresponding button on the pushbutton unit and keeping it depressed. The brake will function again as soon as the button is released.
Info/Illustration
Using the pushbutton on the manipulator with an external power supply
The procedure below details how to release the holding brakes with the pushbuttons, when the manipulator is not connected to the controller.
Step
1.
Action
Connect an external 24VDC power supply to the connector R1.MP on the manipulator 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.
Note/Illustration
Danger!
Incorrect connections can cause all brakes to be released simultaneously!
R1.CP/CS
R1.MP
R1.SMB
0V B14 +24V B16

xx0300000200
Connect to connector R1.MP: 0V: pin B14 or B15 2. Release the holding brake on a particular axis by pressing the corresponding button on the pushbutton unit and keeping it depressed. The brake will function again as soon as the button is released. +24V: pin B16 The brake release unit is equipped with six buttons for controlling the axes brakes. The buttons are numbered according to the numbers of the axes. See the previous figure.
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Using an external voltage supply directly on the respective brake
The procedure below details how to release the holding brake of a specific axis by supplying external voltage directly on the brake.
Step
1.
Action
Every axis has a holding brake built into the axis motor. This holding brake may be released by connecting 24VDC power supply directly to one of the connectors in the motor.
Note/Illustration
Make the connection to current motor according to the Circuit Diagram See chapter Circuit diagram in the Product manual, reference information.
Danger!
When power is connected directly to the brake cable, the brake will be released immediately when the power is switched. This may cause som unexpected manipulator movements!
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2.2.3 Orienting and securing the manipulator
General
This section details how to orient and secure the manipulator to the base plate after fitting it to the foundation.
Securing parts/ facts
The table below specifies the type of securing screws and washers to be used to secure the manipulator to the base plate/foundation.
Securing parts/fact
Securing screws, oiled Washers
Dimension/art. no.
M20 Thickness: 3 mm Outer diameter: 36 mm Inner diameter: 21 mm 2151 0024-169
Amount/Note
3 pcs 3 pcs
Guide sleeves
2 pcs Added to the rear bolt holes, to allow the same robot to be re-mounted without program adjustments. Oiled screws
Tightening torque Level surface requirements
350 - 400 Nm
0.5
xx0300000251
Hole configuration and dimensions
The illustration below shows the hole configuration and hole dimensions of the manipulator base, seen from below. The cut x-x shows the dimension of the rear bolt holes, where the guide sleeves may be used.
22 B 22
35
xx0300000252
A B
Rear bolt holes Center line, axis 1
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Orienting and securing the manipulator
The procedure below details how to orient and secure the manipulator to the base plate after fitting the plate to the foundation.
Warning! The manipulator weighs 1300 kg! All lifting equipment used must be dimensioned accordingly!
Step
1. 2. 3.
Action
Lift the manipulator. Move the manipulator to the vicinity of the installation site.
Info/Illustration
Detailed in section Lifting manipulator with round slings on page 42.
Fit two guide sleeves to the rear bolt holes in Art. no. is specified in Securing the base. parts/facts on page 49. Shown in the figure Hole configuration and dimensions on page 49. Guide the manipulator gently using M20 screws while lowering it into its mounting position. Fit the securing screws and washers in the base attachment holes. Specified in Securing parts/facts on page 49. Attachment holes shown in the figure Hole configuration and dimensions on page 49.
4.
5.
6.
When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined in section Loads on foundation, manipulator on page 35.
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2.2.4 Fitting equipment on manipulator
General
The manipulator features mounting holes for additional equipment. Access to any of the following mounting holes may be obstructed by any additional cabling, equipment etc. fitted by the robot user. Make sure the required mounting holes are accessible when planning the robot cell. Never drill a hole in the manipulator without first consulting ABB!
Fitting equipment on upper arm, IRB 4400/45, /60, /L30, /S
The illustration below shows the mounting holes available for fitting extra equipment on the upper arm for robot versions IRB 4400/45, /60, /L30, /S. The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes.
A 250 175 A
150
300
D 390 D 20o B -B 15 150 B
340 144 115 54
H
29.5 29.5 106 200 110
D-D
A- A
I J
K
xx0300000264
E F G H I J K
Max. 15 kg M8 (2x), holes used if option 043 is chosen. Depth of thread: 9 mm M8 (3x) Depth of thread: 14 mm 571 mm for IRB 4400/45 and /60. 1071 mm for IRB 4400/S and /L30 Max. 5 kg for IRB 4400/45 and /60 at max. handling weight 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! M6 (2x), tapped depth 12 mm
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Fitting equipment on upper arm, IRB 4400/L10
The illustration below shows the mounting holes available for fitting extra equipment on the upper arm for robot versions IRB 4400/L10. The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes.
A
250 175
150
300
390
20 o
150
B-B
110 115 1221 54
C G
300
240 110
A-A
F
xx0300000265
C D E F G
Max. 15 kg M6 (2x) Depth of thread: 9 mm M8 (3x) Depth of thread: 14 mm Max. 2 kg M5 (2x)
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Fitting equipment on gearbox unit
The illustration below shows the mounting holes available for fitting extra equipment on the gearbox unit. The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes.
195
10
120 o (3x)
C- C
xx0300000266
A B
M8 (3x), R=2. Depth 16 mm (if option 623 is chosen, these holes are occupied) Max. 35 kg for IRB 4400/45, /60, /L10, /L30 (0 kg for IRB 4400/S)
Fitting equipment on mounting flange, IRB 4400/ 45, /60, /L30, /S
The illustration below shows the mechanical interface for the mounting flange, robot version IRB 4400/45, /60, /L30 and /S.
A 8 -0 A 8
+0.015 0.05 A
M10 (6x) R 50
9 15 A A-A
xx0300000267
60o
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Fitting equipment on mounting flange, IRB 4400/ 10
The illustration below shows the mechanical interface for the mounting flange, robot version IRB 4400/L10.
6 -0
+0.012
H7
C B
0.05 B
M6 (6x) R =25
A 7 A- A
xx0300000268
The hole can go through
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2.2.5 Loads
2.2.5 Loads
General
Any loads mounted on the manipulator must be defined correctly and carefully (with regard to the position of center of gravity and inertia factor) in order to avoid jolting movements and overloading the motors. If this is not done correctly operational stops may result.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the Product Specification. The loads must also be defined in the software as detailed in Users Guide.
Stop time and braking distances
Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB Robotics.
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2.3.1 Introduction
2.3: Restricting the working range 2.3.1 Introduction
General
When installing the manipulator, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. The working range of the manipulator may be limited to eliminate the risk of collisions. The following axes may be restricted:
Axis 1, hardware (mechanical stop) and software (signal from adjustable position switch) Axis 2, hardware (mechanical stop) Axis 3, software (signal from limit switch)
This section describes the use of the mechanical stops and/or the position switches. Limiting the working space using software is described in section System Parameters in the Users Guide . Art. no. for the manual is specified in section Document references .
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2.3.2 Mechanically restricting the working range of axis 1
Mechanically restricting the working range
The working range of axis 1 can be restricted mechanically by fitting additional mechanical stops to the base, as detailed in this section.
Required equipment Equipment, etc.

Mechanical stop, axis 1
Spare part no. Art. no.

3HAB 3833-1
Note
Includes 2 additional stop lugs, 8 attachment screws, 8 plain washers and a label 4 pcs/lug, included in 3HAB 3833-1 M12x60 4 pcs/lug, included in 3HAB 3833-1 13x24x2,5
Attachment screw
9ADA 183-71
Washer
9ADA 312-9
Standard toolkit
3HAC 17594-1
The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
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Additional stops
The additional stops are fitted as shown in the figure below.
D E F C
xx0300000258
B C D E F
Mechanical stop lugs Attachment screw and washer Stop pin Max. working range with stop lugs (250) Min. working range with stop lugs (127)
Fitting, mechancial stop axis 1
The procedure below details how to fit the additional mechanical stop to the base. Mounting instructions are also supplied with the kit.
Step
1. 2.
Action
Info/Illustration
Determine the position of the stop lugs and See the figure Additional stops on page mark the hole positions on the base. 58 for guidance. Drill 10.2 mm to a maximum depth of 45 mm and tap with M12 thread. Min. thread depth 35 mm. Fit the stop lugs firmly with attachment screws and washers according to the figure Additional stops on page 58. Specified in Required equipment on page 57. M12x60, tightening torque: 82 Nm, oil lubrication.
3.
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Mechanically restricting the working range
The working range of axis 2 can be restricted mechanically by fitting additional mechanical stops (spacers and dampers) to the lower arm and gearbox unit axis 1-3, as detailed in this section.

Mechanical stop, axis 2

3HAC 4225-1
Note
Includes spacers, dampers, attachment screws and nuts.
Spacer (damper) Spacer Standard toolkit
3HAB 9185-1 3HAC 3962-1 3HAC 17594-1 The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
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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
E
C C
D D
G H
C-C D-D
xx0300000260
A B C D E F G 60
View A of the lower arm View B of the lower arm Cut of the mech stop attachment Spacer Attachment screw, spacer (+nut) Damper Attachment screw, damper (+nut) Revision 3HAC 022032-001

Working ranges
The working range of axis 2 can be restricted according to the table below. The table applies to all robot versions except IRB 4400/FS.
Working range
+95/ -70 +95/ -40 +95/ -10 +65/ -70 +65/ -40 +65/ -10 +35/ -70 +35/ -40 +35/ -10 +5/ -70(not applicable on IRB 4400/S) +5/ -40(not applicable on IRB 4400/S) +5/ -10(not applicable on IRB 4400/S)
Damper, qty
2 2 2 4 4 4 6 6 6 8
Spacer, qty
2 2 2 2 2 2 2 2
Each damper is fitted with: 2 attachment screws and 2 hexagon nuts. Each spacer is fitted with: 1 attachment screw and 1 hexagon nut.
Fitting, mechancial stop axis 2
The procedure below details how to fit the additional mechanical stop to the lower arm and the gearbox unit. Mounting instructions are also supplied with the kit.
Step
1. 2.
Action
Info/Illustration
Determine the working range restriction. See Working ranges on page 61. Fit both the spacers to either side of the Shown in the figure Additional stops on gearbox unit, with the attachment screws page 60. and nuts, spacer. Art. no. is specified in Required equipment on page 59. Attachment screw: 1 pc/spacer, M16x70. Tightening torque: 156 Nm. Fit the dampers to both sides of the lower Shown in the figure Additional stops on arm with the attachment screws and page 60. nuts, damper. Art. no. is specified in Required equipment on page 59. Attachment screws: 2 pcs/damper, M10x60. Tightening torque: 49 Nm.
3.
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2.3.4 Electrically restricting the working range of axis 3
Electrically restricting the working range
The working range of axis 3 can be limited by fitting an electric switch on the gearbox for axis 3, which senses the current position via a cam.
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 F K J
M
x
x-x
R3.LS1 R3.LS2
xx0300000262
A B C D E F G H I J K L M
Sealing with dust lip (3HAB 3701-14) Stud (2122 2012-867) All screws are locked with locking liquid Tap (3HAB 3798-1) Hexagon nut (9ADA 267-7) Disc (3HAB 3799-1) Screw (9ADA 618-44) Cam (3HAB 3800-1) Bracket (3HAB 8400-1) Limit switch complete (3HAB 8400-1) Screw (9ADA 629-50) Attachment screw (9ADA 183-35) Retaining ring (9ABA 135-18), reducing coupling (2686 015-3), washer (2152 398-3)
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Electrical stop, axis 3

3HAB 3795-1
Note
Includes all spare parts shown in the figure Electrical stop on page 62. Loctite 242 The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Locking liquid Standard toolkit
1269 0014-410 3HAC 17594-1
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. Circuit Diagrams
See chapter Circuit Diagrams in the Product manual, reference information.
Fitting, electrical stop axis 3
The procedure below details how to fit the electrical stop to axis 3. Mounting instructions are also supplied with the kit.
Step
1.
Action
Remove the covers (A) from axis 3.
Info/Illustration
xx0300000263
2. 3.
All screws are locked with locking liquid , when fitted. Fit the electrical stop according to the figure Electrical stop on page 62.
Specified in Required equipment on page 63.
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2.3.5 Unlimited working range
Resetting the work area for an axis
The function "Resetting the work area for an axis", included in Advanced Motions 3.0, can also be used for axis 4. To enable this function, the mechanical stop on axis 4 should be removed. Follow the procedure below to dismantle the mechanical stop. Also, see the Foldout section in the Repair Manual .
Location of mechanical stop, axis 4
The mechanical stop of axis 4 is located as shown in the figure below. A more detailed view is shown in the Foldout section in the Repair Manual!
A
x
C
x
x-x
xx0300000176
A B C
Mechanical stop axis 4 Damper axis 4 Attachment screws, mech stop
Removal of mechanical stop, axis 4
The procedure below details how to remove the mechanical stop of axis 4, to enable the function "Resetting the work area for an axis".
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.
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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 function Resetting the work area for an axisis used, or if the robot is jogged uncalibrated.
Step
1. 2. 3. 4.
Action
Loosen the attachment screws, mech stop and remove the mechanical stop, axis 4 . Slowly rotate axis 4 until the damper is visible through the hole. Remove the damper. Refit the mechanical stop to the axis 4 with its attachment screws.
Info/Illustration
Shown in the figure Location of mechanical stop, axis 4 on page 64.
4 pcs, M8x16. Tightening torque: 24 Nm.
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2.4.1 Customer connection on manipulator
2.4: Electrical connections 2.4.1 Customer connection on manipulator
General
For connection of extra equipment to the manipulator, cables and air hose are integrated into the manipulators cabling, and there is one FCI UT071823SH44N and one FCI UT071412SH44N connector on the rear part of the upper arm. The customer connections are located on the manipulator as shown in the figure below.
C
xx0300000270
A B C
R1.CP, R1.CS, Air R1/4" R2.CP, R2.CS, Air R1/4" R3.CP, R3.CS, Air R1/4"
Extra equipment connections
Connections to the:
air hose (R1/4) is located on the rear part of the upper arm and at the base. Max. 8 bar. Inner hose diameter: 8 mm. signal cabling (option 042) are located on the front of the upper arm.
Number of signals: 23 (50V, 250mA), 10 (250V, 2A), one protective ground.
Connection sets
To connect power and signal conductors to the manipulator base/upper arm connectors, the following parts are recommended.
Connection set
Connector
Art. no.
3HAC 12275-1
Content
socket for area of 0.14 - 0.5 mm 2 compression gland for cables, diameter 2 x 12 mm key pin
Connection set R1.CP/CS R1.CP/CS (IRB 4400 Protection Standard)
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2.4.1 Customer connection on manipulator
Connection set
Connection set R1.CP/CS F (IRB 4400 Protection Foundry)
Connector
R1.CP/CS
Art. no.
3HAC 12276-1
Content
socket for area of 0.14 - 0.5 mm 2 compression gland for cables, diameters 10 mm and 12 mm key pin pins for cable area of 0.13 - 0.25 mm 2 reduction hose, bottled-shaped reduction hose, angled pins for cable area of 0.13 - 0.25 mm 2 reduction hose, bottled-shaped reduction hose, angled
Connection set R2.CS/ R3.CS R2.CS/R3.CS 3HAC 12327-1 Connection set R2.CP/ R3.CP R2.CP/R3.CP 3HAC 12326-1
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2.4.2 Customer connections on upper arm
Customer connection on upper arm
The figure below shows the customer connections on the upper arm, including the optional signal lamp that can be fitted to the rear of the arm.
A C
B
xx0300000269
A B C D
R2.CP R2.CS Signal lamp (option) R3.H1 +, R3.H2 -
Power supply connections on upper arm Signal name
Customer Terminal Controller

XT6.1 XT6.2 XT6.3 XT6.4 XT6.5 XT6.6
Customer Contact on Upper arm, R2

R2.CP.A R2.CP.B R2.CP.C R2.CP.D R2.CP.E R2.CP.F R2.CP.G (Earth)
Customer Contact on Manipulator base (cable between manipulator and controller not supplied)
RI.CP/CS.A1 RI.CP/CS.B1 RI.CP/CS.C1 RI.CP/CS.D1 RI.CP/CS.A2 RI.CP/CS.B2 RI.CP/CSP Earth
CPA CPB CPC CPD CPE CPF
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Signal name

XT6.H
Customer Contact on Upper arm, R2

R2.CP.H (Key pin) R2.CP.J R2.CP.K R2.CP.L R2.CP.M
Customer Contact on Manipulator base (cable between manipulator and controller not supplied)
RI.CP/CS.C2 RI.CP/CS.D2 RI.CP/CS.A3 RI.CP/CS.B3
CPJ CPK CPL CPM
XT6.7 XT6.8 XT6.9 XT6.10
Signal connections on upper arm Signal name

XT5.1 XT5.2 XT5.3 XT5.4 XT5.5 XT5.6 XT5.7 XT5.8 XT5.9 XT5.10 XT5.11 XT5.12 XT5.13 XT5.14 XT5.15 XT5.16 XT5.17 XT5.18 XT5.19 XT5.20 XT5.21
Customer Contact on Customer Manipulator base Contact on Upper (cable between manipulator arm, R2 and controller not supplied)
R2.CS.A R2.CS.B R2.CS.C R2.CS.D R2.CS.E R2.CS.F R2.CS.G R2.CS.H R2.CS.J R2.CS.K R2.CS.L R2.CS.M R2.CS.N R2.CS.P R2.CS.R R2.CS.S R2.CS.T R2.CS.U R2.CS.V R2.CS.W R2.CS.X R1.CS/CP.B5 R1.CS/CP.C5 R1.CS/CP.D5 R1.CS/CP.A6 R1.CS/CP.B6 R1.CS/CP.C6 R1.CS/CP.D6 R1.CS/CP.A7 R1.CS/CP.B7 R1.CS/CP.C7 R1.CS/CP.D7 R1.CS/CP.A8 R1.CS/CP.B8 R1.CS/CP.C8 R1.CS/CP.D8 R1.CS/CP.A9 R1.CS/CP.B9 R1.CS/CP.C9 R1.CS/CP.D9 R1.CS/CP.A10 R1.CS/CP.B10
CSA CSB CSC CSD CSE CSF CSG CSH CSJ CSK CSL CSM CSN CSP CSR CSS CST CSU CSV CSW CSX
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3.0.1 Introduction
3: Maintenance
3.0.1 Introduction
General
This chapter contains information on how to maintain the equipment described, i.e. how to perform the preventive maintenance activities specified in the maintenance schedule for the same equipment.
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3.1.1 Specification of maintenance intervals
3.1: Maintenance schedule 3.1.1 Specification of maintenance intervals
Description
The intervals may be specified in different ways depending on the type of maintenance 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.
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3.1.2 Maintenance schedule
3.1.2 Maintenance schedule
General
The robot system, consisting of manipulator and controller cabinet, must be maintained regularly 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 intervals
The table below specifies the required maintenance activities and intervals.
Maintenance activity
Replacement Replacement
Equipment
Interval
Detailed in section
Replacement of battery pack, measuring system on page 76 Replacement of signal cabling, upper arm (option 042) on page 138 Inspection of mechanical stop, axis 1 on page 74 Oil change, gearbox axis 4 on page 84 1. Oil change, gearbox axis 5 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
Battery pack, mea- 12-36 mths 1 suring system Signal cabling, upper arm (option 042) Mechanical stop, axis 1 12,000 hrs
Inspection Change Change
Regularly 3
Oil, gearbox axis 4 12,000 hrs 2 Oil, gearbox axes 5 12,000 hrs 2 and 6
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 40C. If the temperature is higher, the oil should be changed! 3. Must be replaced if bent!
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3.2.1 Inspection of mechanical stop, axis 1
3.2: General maintenance activities 3.2.1 Inspection of mechanical stop, axis 1
Location of mechanical stop
The mechanical stop on axis 1 is located on the frame as shown in the figure below.
A
xx0300000182
A B
Mechanical stop pin, axis 1 Set screw

Mechanical stop, axis 1 Standard toolkit

3HAB 3647-1 3HAC 17594-1
Note
Other tools and procedures may be required. See references to these procedures in 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.
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3.2.1 Inspection of mechanical stop, axis 1
Warning! If the mechanical stop has been deformed after a hard collision, it must be replaced!
Step
1.
Action
Check regularly that the pin is not bent or damaged in any other way. If bent/damaged, the pin must be replaced by a new one. Also check that the pin is properly attached.
Info/Illustration
Removal/refitting of the mechanical stop is detailed in section Replacement of mechanical stop pin, axis 1 on page 178.
2.
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3.2.2 Replacement of battery pack, measuring system
Location of battery pack
The battery pack is fit to the serial measurement unit, located inside the base. To access the unit and battery pack, the rear cover plate shown in the figure below must be removed.
xx0300000106
Rear cover plate

Battery pack Battery pack Standard toolkit

4944 026-4 3HAC 16831-1 3HAC 17594-1
Note
Rechargeable nickelcadmium battery. Lithium battery. The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Replacement, battery pack
The procedure below details how to replace the battery pack in the serial 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.
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Step
1.
Action
Set the robot to the MOTORS OFF operating mode. This way the robot does not need to be calibrated after the battery change. Remove the rear cover plate from the base. Loosen the battery terminals from the serial measuring board and cut the clasps that keep the battery pack in place. Remove the old battery pack.
Info/Illustration
2. 3.
Shown in the figure Location of battery pack on page 76.
4. 5. 6.
Fit a new battery pack with two clasps and con- Part no. is specified in Required nect the terminals to the serial measuring board. equipment on page 76. The rechargeable nickel-cadmium battery takes 36 hours to recharge; the mains supply must be switched on during this time.
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3.2.3 Cleaning of manipulator
3.2.3 Cleaning of manipulator
General
Depending on the protection class, different methods of cleaning the manipulator are allowed. This section describes how to clean
the Standard version the Foundry version
Standard version
The protection class is IP54. The exterior of the robot should be cleaned as required. Use a vacuum cleaner or wipe it with a cloth. Do not use compressed air and harsh solvents that can damage the sealing joints, bearings, lacquer or cabling.
Foundry version
The protection class is IP 67, which means that the manipulator is watertight.
Equipment
Steam cleaner
Requirements
water pressure at nozzle: max. 2500 kN/m 2 (25 bar) type of nozzle: fan jet, min. 45spread flow: max. 100 litres/min distance from nozzle to encapsulation: min. 0.4 m water temperature: max. 80C fan jet nozzle should be used, min. 45spread max. water pressure on enclosures: 50 kN/m 2 (0.5 bar) flow: max. 100 litres/min
High pressure water cleaner
Dos and donts!
The section below specifies some special considerations when cleaning the manipulator. Always!
Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels! Always check that all protective covers are fitted to the robot before cleaning!
Never!
Never point the water jet at bearing seals, contacts, and other seals! Never spray from a distance closer than 0.4 m! Never remove any covers or other protective devices before cleaning the robot! Never use any cleaning agents, e.g. compressed air or solvents, other than those specified above! Although the manipulator is watertight, avoid spraying connectors and similar items with a high pressure cleaner!
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3.3.1 Oil in gearbox unit, axis 1-2-3
3.3: Change and checking of oil 3.3.1 Oil in gearbox unit, axis 1-2-3
General
The oil in the gearbox unit, axis 1-2-3, is normally not changed. This section specifies the oil permitted in the unit.
Oil in gears, IRB 4400/45, /60, /L30, /L10
Gear...
Axis 1 Axis 2-3
Art. no.
1171 2016-604 1171 2016-604
Volume
8,200 ml 5,800 ml
Note
The lubricating oil specified above corresponds to:

Mobile Gearlube X 320 Mobilgear 632
Oil in gears, IRB 4400/FS Gear...

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

Mobile Gearlube X 320 Mobilgear 632
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3.3.2 Inspection of oil levels
Location of oil plugs, axes 2 and 3
The oil plug, filling for the gearbox unit, axes 2 and 3, is located as shown in the figure below. The figure shows the location of the axis-2-side and is the same on the opposite side.
xx0300000331
Oil plug, filling
Location of oil plugs, axis 4
The axis 4 gearbox has one oil plug for draining and one oil plug for filling, located as shown in the figure below.
x B A
x-x B
xx0300000220
A B
Upper oil plug, filling Lower oil plug, draining
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Location of oil plugs, axes 5 and 6 (all robot versions except IRB 4400/L10)
The wrist unit has two oil plugs for draining and one oil plug for filling, located as shown in the figure below.
B A
xx0300000223
A B
Oil plug, draining (2 pcs, the other oil plug not shown in figure) Oil plug, filling (also used for draining)
Location of oil plugs, axes 5 and 6 (only IRB 4400/ L10)
The wrist unit has one oil plug for draining the oil and one oil plug for filling, located as shown in the figure below. The oil plug for filling is also used as an air inlet when draining the oil.
B
xx0300000118
A B
Oil plug, draining Oil plug, filling (also used as air inlet when draining)

Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information .
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Equipment, etc.
Note
These procedures include references to the tools required.
Inspection, oil level axis 2-3
The procedure below details how to inspect the oil level of the gearbox unit, axes 2-3.
Step
1. 2. 3. 4.
Action
Remove the oil plug, filling .
Note/Illustration
Shown in the figure Location of oil plugs, axes 2 and 3 on page 80.
Measure the oil level from the oil plug hole. The oil must cover at least half of the lower arm bearing! Required oil level: 225 mm 25 mm. Fill or drain, if necessary. Clean and refit the oil plug. Type of oil is detailed in section Oil in gearbox unit, axis 1-2-3 on page 79.
Inspection, oil level axis 4
The procedure below details how to inspect the oil level of the gearbox, 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!
Step
1. 2. 3. 4.
Action
Move the upper arm to a horizontal position (calibration position). Remove the upper oil plug, filling . Required oil level: 4 mm to the edge of the oil plug hole. Fill with lubricating oil , if necessary.
Info/Illustration
Shown in the figure Location of oil plugs, axis 4 on page 80.
Type of oil is detailed in section Oil change, gearbox axis 4 on page 84.
5.
Refit the oil plug.
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Inspection, oil level axis 5 and 6 (all robot versions except IRB 4400/L10)
The procedure below details how to inspect the oil level of wrist unit, axis 5 and 6 for all robot versions except IRB 4400/L10.
Step
1. 2.
Action
Move the robot to the calibration position.
Note/Illustration
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. Required oil level: on level with the edge of the oil plug hole. 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.
3. 4.
5.
Refit the oil plug.
Inspection, oil level axis 5 and 6 (IRB 4400/L10)
The procedure below details how to inspect the oil level of wrist unit, axis 5 and 6 for robot version IRB 4400/L10.
Step
1.
Action
Move the robot to a position where the upper arm is close to horizontal and axis 4 in the calibration position. Remove the oil plug, filling from the side of the wrist. Required oil level: on level with the edge of the oil plug hole. Fill with lubricating oil , if necessary.
Note/Illustration
2.
Shown in the figure Location of oil plugs, axes 5 and 6 (only IRB 4400/L10) on page 81
3. 4.
Type of oil is detailed in section Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) on page 89.
5.
Refit the oil plug.
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3.3.3 Oil change, gearbox axis 4
Location of oil plugs
The axis 4 gearbox has one oil plug for draining and one oil plug for filling, located as shown in the figure below.
x B A
x-x B
xx0300000220
A B
Upper oil plug, filling Lower oil plug, draining

Lubricating oil Standard toolkit

3HAC 0860-1 3HAC 17594-1
Note
Optimol Optigear BM 100 Volume: 3,400 ml. The contents are defined in section Standard toolkit in the Product manual, reference information. Capacity: 4,000 ml. These procedures include references to the tools required.
Oil collecting vessel Other tools and procedures may be required. See references to these procedures in the step-bystep 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.
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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!
Step
1. 2.
Action
Move the arms backward and the upper arm to a nearly vertical position.
Info/Illustration
Remove the lower oil plug, draining and drain the Shown in the figure Location of oil into an oil collecting vessel. oil plugs on page 84. Capacity of the oil collecting vessel is specified in Required equipment on page 84. Clean and refit the oil plug.
3.
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
Step
1. 2. 3.
Action
Move the upper arm to a vertical position (rear end upwards). Remove the upper oil plug, filling . Fill the gearbox with lubricating oil .
Note/Illustration
Shown in the figure Location of oil plugs on page 84. Amount and art. no. is specified in Required equipment on page 84. Correct oil level is specified in section Inspection of oil levels on page 80.
4.
Clean and refit the oil plug.
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3.3.4 Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10)
The wrist unit has two oil plugs for draining and one oil plug for filling, located as shown in the figure below.
B A
xx0300000223
A B
Oil plug, draining (2 pcs, the other oil plug not shown in figure) Oil plug, filling (also used for draining)


3HAC 0860-1 3HAC 17594-1
Note
Optimol Optigear BM 100 Volume: 3,400 ml The contents are defined in section Standard toolkit in the Product manual, reference information. Capacity: 4,000 ml These procedures include references to the tools required.
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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!
Step
1. 2. 3.
Action
Move the upper arm to a horizontal position and turn axis 4 to the calibration position. Turn axis 4 135.
Info/Illustration
Remove the lower oil plug, draining at the rear of Shown in the figure Location of the wrist. oil plugs on page 86. Capacity of oil collecting vessel is specified in Required equipment on page 86. Remove the other oil plug, draining. Move axis 3 up -15and let the oil run out for a couple of minutes. Turn axis 4 so that the oil plug, filling is facing downwards. Remove the oil plug, axis 5 to drain the oil. Move axis 3 down to 0. Move axis 4 backwards and forwards a couple of times to drain all the oil. Clean and refit the both oil plugs, draining . Shown in the figure Location of oil plugs on page 86.
4. 5. 6. 7. 8. 9. 10.
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
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Step
1. 2. 3.
Action
Move the upper arm to a horizontal position and turn axis 4 to calibration position. Turn axis 4 so that the oil plug, filling is facing upwards. Fill the wrist with lubricating oil through the oil plug hole, filling. Fill in intervals so that the oil runs into the wrist. Clean and refit the oil plug, filling.
Note/Illustration
Shown in the figure Location of oil plugs on page 86. Art. no. and amount is specified in Required equipment on page 86. Correct oil level is specified in section Inspection of oil levels on page 80.
4.
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3.3.5 Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only)
The wrist unit has one oil plug for draining the oil and one oil plug for filling, located as shown in the figure below. The oil plug for filling is also used as an air inlet when draining the oil.
B
xx0300000118
A B
Oil plug, draining Oil plug, filling (also used as air inlet when draining)


3HAC 0860-1 3HAC 17594-1
Note
Optimol Optigear BM 100 Volume: 800 ml The contents are defined in section Standard toolkit in the Product manual, reference information. Capacity: 1000 ml These procedures include references to the tools required.
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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!
Step
1. 2. 3.
Action
Move the upper arm to a horizontal position and turn axis 4 to the calibration position. Remove the oil plug, draining in the wrist. Turn axis 4 to a position where the oil plug, draining is faced downwards and drain the oil into an oil collecting vessel . Also remove the oil plug, filling , in order to use it as an air inlet. Turn axis 4 another 90to allow the remaining oil to be drained. Clean and refit the oil plug, draining.
Info/Illustration
Shown in the figure Location of oil plugs on page 89. Shown in the figure Location of oil plugs on page 89. Capacity of vessel is specified in Required equipment on page 89.
4. 5.
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
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Step
1. 2.
Action
Move the upper arm to a horizontal position and turn axis 4 to the calibration position.
Note/Illustration
Fill the wrist with lubricating oil through the Art. no. and amount are specified in oil plug hole, filling. Required equipment on page 89. Correct oil level is specified in section Inspection of oil levels on page 80. Clean and refit the oil plug, filling.
3.
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4.0.1 Introduction
4: Repair
4.0.1 Introduction
Definitions
This chapter details all repair activities recommended for the manipulator and any external units of the manipulator. It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refitting 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.
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4.1.1 Performing a leak-down test
4.1: General procedures 4.1.1 Performing a leak-down test
General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test.

Leakdown tester Leak detection spray
Spare part no.
Art. no.
3HAC 0207-1
Note
Procedure Step
1. 2.
Action
Finish the refitting procedure of the motor or gear in question.
Note/Illustration
Remove the topmost oil plug on the gear in ques- Art. no. specified above! tion, and replace it with the leakdown tester . Adapters may be required, which are included in the leakdown tester kit. Apply compressed air, and raise the pressure Recommended value: 0.2 - 0.25 with the knob until the correct value is shown on bar (20 - 25 kPa) the manometer. Disconnect the compressed air supply. Wait for approx. 8-10 minutes. No pressure loss If the compressed air is signifimust be detected. cantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease respectively may occur. This is quite normal. Was any pressure drop evident? Localize the leak as detailed below. Remove the leakdown tester, and refit the oil plug. The test is complete. Spray suspected leak areas with leak detection spray . Bubbles indicate a leak. When the leak has been localized: take the necessary measures to correct the leak. Art. no. specified above!
3.
4. 5.
6.
7.
8.
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4.1.2 Mounting instructions for bearings
4.1.2 Mounting instructions for bearings
General
This section details how to mount and grease different types of bearings on the manipulator.
Equipment Equipment, etc. Art. no.

Grease 3HAB 3537-1
Note
Used to grease the bearings, if not specified otherwise.
Assembly of all bearings
Follow the instructions below when mounting a bearing on the manipulator. 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 tapered bearings
Follow the previous instructions for assembly of all bearings, when mounting a tapered bearing 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 pretensioning 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 bearings
The bearings must be greased after assembly, according to instructions below:

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 condition. Revision 95
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4.1.3 Mounting instructions for seals
General
This sections details how to mount different types of seals to the manipulator.
Equipment Equipment, etc.

Grease
Art. no.
3HAB 3537-1
Note
Used to lubricate the seals.
Rotating seals
The procedure below details how to fit rotating seals. Caution! Please observe the following before commencing any assembly of seals: Protect the sealing surfaces during transport and mounting. Keep the seal in its original wrappings or protect it well before actual mounting. The fitting of seals and gears must be carried out on clean workbenches. Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc.
Step
1.
Action
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).
Note
2.
Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced, as it may result in future leakage. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in early as there is a risk of dirt and foreign particles adher- Equipment on page 96. ing to the seal.) Fill the space between the dust tongue and sealing lip to 2/3 with grease. The rubber coated external diameter must also be greased, unless otherwise specified. Mount the seal correctly with a mounting tool. Never hammer directly on the seal as this may result in leakage.
3.
4.
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Flange seals and static seals
The procedure below details how to fit flange seals and static seals.
Step
1.
Action
Check the flange surfaces. They must be even and free from pores. It is easy to check flatness using a gauge on the fastened joint (without sealing compund). If the flange surfaces are defective, the parts may not be used beacuse leakage could occur. Clean the surfaces properly and in accordance with ABB ROBOTICS PRODUCTS recommendations. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Note
2. 3. 4.
O-rings
The procedure below details how to fit o-rings.
Step
1. 2. 3.
Action
Ensure that the correct o-ring size is used. Check the o-ring for surface defects, burrs, shape accuracy, etc. Check the o-ring grooves. The grooves must be geometrically correct and free from pores and contamination. Lubricate the o-ring with grease. Tighten the screws evenly when assembling.
Note
Defective o-rings may not be used. Defective o-rings may not be used.
4. 5.
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4.2.1 Removal of cable harness, axes 1-3
4.2: Complete robot 4.2.1 Removal of cable harness, axes 1-3
Location of cable harness, axes 1-3
The cable harness of axes 1-3 is located throughout the axis 1 of the manipulator as shown in 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 .
A B
xx0300000111
A B
Rear cover plate Connectors at the base. Connectors at the rear cover plate: R1.MP, R1.SMB, R1.CP/CS, R2.MP4-6. Brake release connectors: R2.BU, R2.BU1-3, R2.BU4-6. Connectors at serial measurement unit: R2.SMB, R2.FB1-3, R2.FB4-6.
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Location of cable harness, view X-X
The cable guides in the middle of axis 1 are located as shown in the figure below.
D C H G
E X-X
xx0300000110
C D E G H
Connection box, motor 1. Connectors at motor 1: R3.MP1, R3.FB1. Connection box, motor 2. Connectors at motor 2: R3.MP2, R3.FB2. Connection box, motor 3. Connectors at motor 3: R3.MP3, R3.FB3. Cable guides in the middle of axis 1 Protection plate

Standard toolkit
Art. no.
3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information ! These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below. Circuit Diagram
See chapter Circuit diagram in the Product manual, reference information.
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4 Repair
Removal, cabling axes 1-3
The procedure below details how to remove the cable harness from the 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, especially 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.
Step
1. 2. 3.
Action
Remove the rear cover plate . Remove the serial measurement unit.
Info/Illustration
Shown in the figure Location of cable harness, axes 1-3 on page 98. Removal detailed in section Removal, serial measurement unit on page 174.
Loosen the connectors R1.MP1, R2.FB1- Shown in the figure Location of cable 3, R2.BU, R2.BU1-3 . Also loosen the harness, axes 1-3 on page 98. earth connections. Cut all the ties around bundle. Remove the cable bracket inside the base. Remove the cable guides and the protec- Shown in the figure Location of cable tion plate in the middle of axis 1. harness, view X-X on page 99. Remove the covers from the connections boxes for the motors in axes 1-2-3. Loosen all the connectors to the motors of Shown in the figure Location of cable axes 1-2-3. harness, view X-X on page 99. Remove the connection boxes from the motors 1-2-3. Feed the cabling up through the middle of axis 1 and remove the complete cabling. Tip! Gather the loose cabling and connectors into a package with tape in order to protect the connectors and make the cabling easier to handle.
4. 5. 6. 7. 8. 9. 10.
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4.2.2 Refitting of cable harness, axes 1-3
The cable harness of axes 1-3 is located throughout the axis 1 of the manipulator as shown in 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 .
A B
xx0300000111
A B
Rear cover plate Connectors at the base. Connectors at the rear cover plate: R1.MP, R1.SMB, R1.CP/CS, R2.MP4-6. Brake release connectors: R2.BU, R2.BU1-3, R2.BU4-6. Connectors at serial measurement unit: R2.SMB, R2.FB1-3, R2.FB4-6.
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D C H G
E X-X
xx0300000110
C D E G H

Cable harness, axes 1-3 Gasket 3HAC 4432-1

3HAC 4137-1
Note
Between the motor and the connection box, axes 1, 2 and 3. Replace if damaged.
Standard toolkit
3HAC 17594-1
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. 102 Revision -
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4 Repair
Equipment, etc.
Circuit Diagram
Note
See chapter Circuit diagram in the Product manual, reference information . Details how to calibrate the robot with the pendulum. Art. no. is specified in section Document references in the Product manual, reference information .
Calibration Pendulum Instruction
Refitting, cabling axes 1-3
The procedure below details how to refit the cable harness to axes 1-3.
Step
1.
Action
Info/Illustration
Feed the cable harness, axes 1-3 through the Art. no. is specified in Required protection plate and down through the middle of equipment on page 102. axis 1. Tip! Gather the loose cabling and connectors into a package with tape in order to protect the connectors and make the cabling easier to handle. Refit the connection boxes to the motors 1-2-3. Replace the gaskets if they are damaged. Reconnect the connectors in the motors 1-2-3. Part no. is specified in Required equipment on page 102. Shown in the figure Location of cable harness, view X-X on page 102.
2. 3.
4.
Refit the cable guide and the protection plate in Shown in the figure Location of the middle of axis 1. cable harness, view X-X on page 102. Secure the cabling with straps, according to fold- See the Foldouts in the Product out 3. manual, reference information . Refit the cable bracket inside the base.
5. 6.
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Step
7. 8. 9. 10.
Action
Info/Illustration
Reposition the cabling inside the base according See the Foldouts in the Product to foldout 4. manual, reference information . Reconnect all the connectors at the base. Refit the serial measurement unit. Refit the rear cover plate . Detailed in Refitting, serial measurement unit on page 175. Shown in the figure Location of cable harness, axes 1-3 on page 101. Calibration is detailed in chapter Calibration on page 219. If the robot is calibrated with the Calibration Pendulum, follow the Calibration Pendulum Instruction , enclosed with the calibration toolkit. Art. no. for the instruction is specified in section Document references in the Product manual, reference information .
11. 12.
Refit the covers of the connection boxes. Recalibrate the robot!
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.
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The cable harness of axes 4-6 is located throughout the manipulator as shown in 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 .
F I J X X
A B
xx0300000112
A B
Rear cover plate Connectors at the base. Connectors at the rear cover plate: R1.MP, R1.SMB, R1.CP/CS (customer connection), R2.MP4-6. Brake release connectors: R2.BU, R2.BU1-3, R2.BU4-6. Connectors at serial measurement unit: R2.SMB, R2.FB1-3, R2.FB4-6. Connection box, motor 4, 5 and 6. Connectors to the motors at upper arm: R3.MP4, R3.MP5, R3.MP6, R3.FB4, R3.FB5, R3.FB6. Customer connections: R2.CP, R2.CS. Cable bracket inside the lower arm Cable bracket at the upper arm
I J
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D C H G
E X-X
xx0300000110
C D E G H

Standard toolkit
Art. no.
3HAC 17594-1
Note
See chapter Circuit diagram in the Product manual, reference information .
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Removal, cabling axes 4-6
The procedure below details how to remove the cable harness from the axes 4-6.
Step
1. 2. 3. 4.
Action
Remove the cover of the connection box for motors 4-5-6. Remove the rear cover plate. Remove the serial measurement unit.
Info/Illustration
Shown in the figure Location of cable harness, axes 4-6 on page 105. Detailed in section Removal, serial measurement unit on page 174.
Loosen the connectors R2.MP4-6, R2.FB4- Shown in the figure Location of cable 6, R2.BU4-6, R1.CP/CS. Also loosen the harness, axes 4-6 on page 105. earth connections. Cut all the straps around the bundle. Remove the cable bracket inside the base. Remove the cable guides and protection plate in the middle of axis 1. Loosen the cable brackets (A) between gearboxes 2 and 3 and cut the strap around them. Shown in the figure Location of cable harness, view X-X on page 106.
5. 6. 7. 8.
A
xx0300000113
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4 Repair
Step
9.
Action
Feed the cabling and air hose, if any, up through axis 1. Tip! Gather the loose cabling and connectors into a package with tape in order to protect the connectors and make the cabling easier to handle. Loosen the cable bracket inside the lower arm and undo the two screws.
Info/Illustration
10. 11. 12.
Shown in the figure Location of cable harness, axes 4-6 on page 105.
Loosen the cable bracket at the upper arm . Shown in the figure Location of cable harness, axes 4-6 on page 105. Loosen the all the connectors to the motors Shown in the figure Location of cable at the upper arm and customer connections, harness, axes 4-6 on page 105. if any. Remove the connection box together with the cabling.
13.
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The cable harness of axes 4-6 is located throughout the manipulator as shown in 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 .
F I J X X
A B
xx0300000112
A B
Rear cover plate Connectors at the base. Connectors at the rear cover plate: R1.MP, R1.SMB, R1.CP/CS (customer connection), R2.MP4-6. Brake release connectors: R2.BU, R2.BU1-3, R2.BU4-6. Connectors at serial measurement unit: R2.SMB, R2.FB1-3, R2.FB4-6. Connection box, motor 4, 5 and 6. Connectors to the motors at upper arm: R3.MP4, R3.MP5, R3.MP6, R3.FB4, R3.FB5, R3.FB6. Customer connections: R2.CP, R2.CS. Cable bracket inside the lower arm Cable bracket at the upper arm
I J
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D C H G
E X-X
xx0300000110
C D E G H

Cable harness, axes 4-6 Gasket 3HAC 3676-1

3HAC 7822-1
Note
3 pcs Between the motor and the connection box. Replace if damaged.
Standard toolkit
3HAC 17594-1
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Revision -
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Equipment, etc.
Circuit Diagram
Note
See chapter Circuit diagram in the Product manual, reference information . Details how to calibrate the robot with the calibration pendulum. Art. no. is specified in section Document references in the Product manual, reference information .
Connection box, upper arm
The figure below shows the location of the motors, connectors and cabling in the upper arm connection box.
A2
B1
D A A1 C1
B B2 C2 C
xx0300000116
F E
A A1 A2 B B1 B2 C C1 C2 D E F
Axis 4 motor Connector R3.MP4 Connector R3.FB4 Axis 5 motor Connector R3.MP5 Connector R3.FB5 Axis 6 motor Connector R3.MP6 Connector R3.FB6 Protection plate Cable strap, indoor cable strap, outdoor
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Refitting, cabling axes 4-6
The procedure below details how to refit the cable harness to the axes 4-6.
Step
1.
Action
Check the position of the three gaskets , located between the motors and the connection box. Replace them if damaged. Refit the connection box. Make sure the gaskets are seated properly!
Info/Illustration
Part no. is specified in Required equipment on page 110.
2. 3.
Reconnect all the connectors and reposition Connectors and correct positioning the cabling inside the connection box using are shown in the figure Connection straps. box, upper arm on page 111. Refit the protection plate in the connection box. Run the cabling through the lower arm. Refit the cable bracket at the upper arm. Shown in the figure Location of cable harness, axes 4-6 on page 109. Shown in the figure Connection box, upper arm on page 111.
4. 5. 6. 7. 8. 9.
Refit the cable bracket inside the lower arm. Shown in the figure Location of cable harness, axes 4-6 on page 109. Feed the cabling through the protection plate and down through the axis 1. Refit the cable brackets (A) between the gearboxes of axes 2 and 3 and strap the cabling. Shown in the figure Location of cable harness, view X-X on page 110.
A
xx0300000113
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Step
10. 11.
Action
Refit the cable bracket inside the base.
Info/Illustration
Put straps around the bundle and position See the Foldout chapter . the cabling at the base according to foldout 4. Reconnect all the connectors at the base. Refit the serial measurement unit. Refit the rear cover plate. Refit the cover of the connection box in the upper arm. Recalibrate the robot! Calibration is detailed in chapter Calibration on page 219. If the robot is calibrated with the Calibration Pendulum, follow the Calibration Pendulum Instruction , enclosed with the calibration toolkit. Art. no. for the instruction is specified in section Document references in the Product manual, reference information . Detailed in Refitting, serial measurement unit on page 175. Shown in the figure Location of cable harness, axes 4-6 on page 109.
12. 13. 14. 15. 16.
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4.2.5 Removal of complete arm system
Location of complete arm system
The complete arm system includes the lower arm and the complete upper arm, as shown 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 D C E
xx0300000143
A B C D E
Lower arm Upper arm Attachment screws and friction washers, lower arm Parallel arm V-ring between lower arm and gearbox axis 3

Standard toolkit

3HAC 17594-1
Note
114
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4 Repair
Removal, complete arm system
The procedure below details how to remove the complete arm system 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 complete arm system weighs xx kg! All lifting equipment used must be dimensioned accordingly!
Step
1. 2. 3.
Action
Remove the tie rod. Remove the cabling down to axis 1. Move the upper arm into a resting position against the lower arm. Lock the upper arm in this position with securing slings around the lower and upper arm (A), as shown in the figure to the right. Note! If the arms are not properly secured, the upper arm may move during the lift and cause a drop of the complete arm system.
Info/Illustration
Detailed in section Removal of tie rod on page 153. Detailed in section Removal of cable harness, axes 4-6 on page 105.
xx0300000142
4. 5. 6. 7. 8.
Unload the weight of the arm system with lifting slings and a crane. Remove the balancing device. Remove the parallel arm. Remove the attachment screws and friction washers, lower arm . Lift away the complete arm system. Make sure the upper and lower arm are properly secured to each other during the lift. Revision 115 Detailed in section Removal of balancing device on page 164. Detailed in section Removal of parallel arm /Removal of bearing on page 158. Shown in the figure Location of complete arm system on page 114.
3HAC 022032-001
4 Repair
4.2.6 Refitting of complete arm system
Location of complete arm system
The complete arm system includes the lower arm and the complete upper arm, as shown 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 D C E
xx0300000143
A B C D E
Lower arm Upper arm Attachment screws and friction washers, lower arm Parallel arm V-ring between lower arm and gearbox axis 3

V-ring

3HAC 3773-11
Note
2 pcs On both sides of the lower arm, in the frame.
Grease Standard toolkit
3HAB 3537-1 3HAC 17594-1
Used to grease sealings and bearings. The contents are defined in section Standard toolkit in the Product manual, reference information.
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Equipment, etc.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Calibration Pendulum Instruction
Note
Art. no. is specified in section Document references in the Product manual, reference information.
Refitting, complete arm system
The procedure below details how to refit the complete arm system 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. Caution! The complete arm system weighs xx kg! All lifting equipment used must be dimensioned accordingly!
Step
1. 2.
Action
Check and grease both of the V-rings in the frame. Replace if damaged. Lift the arm system into mounting position. Make sure the arms are properly secured to each other (A), as shown in the figure to the right.
Info/Illustration
xx0300000142
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4 Repair
Step
3.
Action
Info/Illustration
Secure the arm system to the gearbox axis 2 with 10 pcs, M16x55. Tightening the attachment screws and friction washers. torque: 260 Nm. Make sure both V-rings are seated properly! Shown in the figure Location of complete arm system on page 116. Grease the bearing seating of the parallel arm in the lower arm, to prevent clicking during operation. Refit the parallel arm. Detailed in section Refitting of parallel arm /Refitting of bearing on page 161. Detailed in section Refitting of balancing device on page 168.
4.
5.
6. 7. 8. 9.
Refit the balancing device. Move the upper arm to a horizontal position with a crane. Refit the tie rod. Refit the cabling to the upper arm.
Detailed in section Refitting of tie rod on page 155. Detailed in section Refitting of cable harness, axes 4-6 on page 109. Calibration with the pendulum is detailed in Calibration Pendulum Instruction, enclosed with the toolkit. Other calibration is detailed in section Calibration on page 219.
10.
Recalibrate the robot!
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4.3.1 Removal of complete upper arm
4.3: Upper arm 4.3.1 Removal of complete upper arm
Location of upper arm
The complete upper arm includes the wrist unit and is located as shown 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!
C B
x
D I J F G E H
x-x
xx0300000129
A B C D E F G H I J
Upper arm Connectors of motors, axes 4, 5 and 6 Connection box, upper arm Calibration plate, axis 3 VK cover KM nut Screw Bearing Sealing ring Shaft end
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Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information. Used to pull out the shaft. These procedures include references to the tools required.
Dismounting tool Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.
3HAC 0163-1
Removal, upper arm
The procedure below details how to remove the complete upper arm 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 complete upper arm weighs xx kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!
Step
1. 2. 3. 4. 5. 6. 7.
Action
Move the upper arm to a horizontal position. Secure the weight of the upper arm with lifting slings and a crane. Remove the tie rod.
Info/Illustration
Detailed in section Removal of tie rod on page 153.
Loosen the connectors of motors, axes 4, 5 and Shown in the figure Location of 6. upper arm on page 119. Remove the connection box, upper arm from the Shown in the figure Location of motors. upper arm on page 119. Remove the calibration plate, axis 3 . Remove the VK covers on both sides of the upper arm. Be careful with the bearing beneath the cover! Make a hole in the outer edge of the cover and bend it away. Undo the KM nuts . Shown in the figure Location of upper arm on page 119. Shown in the figure Location of upper arm on page 119.
8.
Shown in the figure Location of upper arm on page 119.
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Step
9. 10. 11. 12.
Action
Remove the screws . Pull out the shaft with the dismounting tool . Mark the shafts (left and right)!
Info/Illustration
Shown in the figure Location of upper arm on page 119. Art. no. is specified in Required equipment on page 120.
Remove the sealings and bearings , if damaged. Shown in the figure Location of upper arm on page 119. Remove the upper arm from the manipulator.
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4.3.2 Refitting of complete upper arm
Location of upper arm
The complete upper arm includes the wrist unit and is located as shown 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!
C B
x
D I J F G E H
x-x
xx0300000129
A B C D E F G H I J
Upper arm Connectors of motors, axes 4, 5 and 6 Connection box, upper arm Calibration plate, axis 3 VK cover KM nut Screw Bearing Sealing ring Shaft end

Sealing ring Taper roller bearing VK cover

3HAC 7877-1 3HAA 2103-13 3HAC 12165-1
Note
122
Revision -
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Equipment, etc.
Shaft end Grease Locking liquid Standard toolkit

3HAC 4744-1 3HAB 3537-1
Note
Used to grease the bearing. Loctite 243 The contents are defined in section Standard toolkit in the Product manual, reference information. . Used to fit the inner ring of the bearing. Contains two separate parts. Used to evacuate air when refitting VK-cover, if the cover has no grooves for venting. These procedures include references to the tools required.
3HAC 17594-1
Mounting tool
3HAB 1463-1
De-air tool
3HAC 8704-1
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below. Calibration Pendulum Instruction
Art. no. is specified in section Document references in the Product manual, reference information..
Refitting, upper arm
The procedure below details how to refit the complete upper arm 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. Caution! The complete upper arm weighs xx kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!
Step
1.
Action
Fit the sealings and the outer ring of the bearings in the upper arm, if removed. The bearing must be completely filled with grease. Lower the upper arm into mounting position.
Info/Illustration
Shown in the figure Location of upper arm on page 122. Part no. is specified in Required equipment on page 122.
2.
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Step
3.
Action
Refit both shaft ends.
Info/Illustration
Shown in the figure Location of upper arm on page 122. Part no. is specified in Required equipment on page 122. Shown in the figure Location of upper arm on page 122. 2 pcs, tightening torque: 470 Nm.
4.
Insert both screws.
5.
If the bearing is removed, the inner ring of Art. no. is specified in Required equipthe bearing is fitted as follows: ment on page 122. Fit the holding-on tool (part A of the C mounting tool ) on the right side of the upper arm (seen from behind). Fit the inner ring (C) of the bearing on the left side of the upper arm, using the press tool (part B of the mounting tool). Remove the holding-on tool and fit the inner ring also on that side.
B
xx0300000130
6. Apply locking liquid on the threads of the KM nut.
A: Holding-on tool B: Press tool C: Inner ring
Locking liquid specified in Required equipment on page 122 Shown in the figure Required equipment 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. Note! If the covers have no grooves for venting, the air must be evacuated by using the de-air tool (A) . Also use a clamp as an aid in positioning the covers tilted, to avoid overpressure. Part no. is specified in Required equipment on page 122. Shown in the figure Location of upper arm on page 122.
A
xx0300000134
A: De-air tool, used if the VKcover has no grooves for venting.
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Step
9. 10. 11. 12. 13.
Action
Refit the tie rod. Refit the calibration plate, axis 3. Refit the connection box.
Info/Illustration
Detailed in section Refitting of tie rod on page 155. Shown in the figure Location of upper arm on page 122. Shown in the figure Location of upper arm on page 122.
Reconnect the connectors to motors, axes Shown in the figure Location of upper 4, 5 and 6. arm on page 122. Recalibrate the robot! Calibration with the pendulum detailed in Calibration Pendulum Instruction , enclosed with the toolkit. Other calibration is detailed in section Calibration on page 219.
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4.3.3 Removal of wrist unit
Location of wrist unit
The wrist unit is located in the upper arm as shown in the figure below. Removal/refitting 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 B C D
Wrist unit O-ring Sealing surface between wrist unit and upper arm tube Attachment screws and washers

Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information.. These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.
Removal, wrist unit
The procedure below details how to remove the wrist unit from the manipulator.
Note! This component includes a complete unit comprising motors and gearboxes. It is a replacement 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.
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Step
1.
Action
Drain the oil from the wrist unit.
Info/Illustration
Draning detailed in sections Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10) on page 86.
2.
Remove the attachment screws and washers, (A).
A
xx0300000148
Wrist unit on robot version IRB 4400/45, /60, /L30, /S.
xx0300000149
3. Remove the wrist unit from the upper arm.
Wrist unit on robot version IRB 4400/ L10.
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4.3.4 Refitting of wrist unit
Location of wrist unit
The wrist unit is located in the upper arm as shown in the figure below. Removal/refitting 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 B C D
Wrist unit O-ring Sealing surface between wrist unit and upper arm tube Attachment screws and washers

Wrist unit (IRB 4400/45, /60, /L30, /S) Wrist unit (IRB 4400/L10) O-ring (IRB 4400/45, /60, /L30, /S) O-ring (IRB 4400/L10) 128

3HAB 8271-1 3HAB 9398-1 2152 2012-541 3HAB 3772-12
Note
Revision -
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Equipment, etc.
Grease Flange sealing Standard toolkit

3HAB 3537-1 1234 0011-116 3HAC 17594-1
Note
Used to lubricate the oring groove. Loctite 574 The contents are defined in section Standard toolkit in the Product manual, reference information.. Used when mounting the wrist unit to robot version IRB 4400/L10. These procedures include references to the tools required.
Measuring tool
3HAB 7887-1
Refitting, wrist unit IRB 4400/45, / 60, /L30, /S
The procedure below details how to refit the wrist unit to robot versions IRB 4400/45, /60, / L30, /S
Note! This component includes a complete unit comprising motors and gearboxes. It is a replacement 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.
Step
1.
Action
Lubricate the o-ring groove in order to position the o-ring . Fit the o-ring to the wrist.
Info/Illustration
Part no. is specified in Required equipment on page 128. Shown in the figure Location of wrist unit on page 128.
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Step
2.
Action
Apply flange sealing to the surface of the wrist that will seal against the upper arm tube.
Info/Illustration
Specified in Required equipment on page 128. Sealing surface shown in the figure Location of wrist unit on page 128.
3.
Refit the wrist with attachment screws and washers (A).
A
xx0300000148
4. Fill the wrist unit with oil.
A: 8 pcs, M10x35. Tightening torque: 41 Nm.
Detailed in section Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10) on page 86. Calibration with the pendulum is detailed in the Calibration Pendulum Instruction , enclosed with the toolkit. Other calibration is detailed in section Calibration on page 219.
5.
Refitting, wrist unit IRB 4400/L10
The procedure below details how to refit the wrist unit to robot version IRB 4400/L10.
Note! This component includes a complete unit comprising motors and gearboxes. It is a replacement 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!
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- 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.
Step
1.
Action
Lubricate and fit the o-ring to the wrist unit .
Note/Illustration
Part no. is specified in Required equipment on page 128. Shown in the figure Location of wrist unit on page 128.
2. 3. 4.
Move the upper arm to a vertical position, wrist side pointing upwards. Refit the wrist unit. Do not tighten the attachment screws! Release the brakes on axes 5 and 6 (one at a Art. no. is specified in Required time) and fit the measuring tool at the rear of equipment on page 128. the motor. Push the wrist to locate the smallest play. Adjustment of play is detailed in section Refitting of motors axis 5 and 6 .
5.
B
xx0300000153
Upper arm seen from front A: Gears on drive shaft 6. Tighten the attachment screws and washers (A). B: Gears on wrist
xx0300000149
7. 8. Check the play by moving axes 5 and 6 by hand. Fill the wrist unit with oil.
A: 6 pcs, M8x30. Tightening torque: 34 Nm.
Detailed in section Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) on page 89.
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Step
9.
Action
Note/Illustration
Calibration with the pendulum is detailed in the Calibration Pendulum Instruction , enclosed with the toolkit. Other calibration is detailed in section Calibration on page 219.
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4.3.5 Replacement of arm house unit, axis 4
Location of arm house unit
The arm house unit includes the axis 4 housing and the upper arm tube. It is located as shown 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!
xx0300000183
A B
Upper arm tube Axis 4 housing

Arm house unit

3HAC 16670-1
Note
Includes axis 4 housing, upper arm tube, motors.
Arm house unit (Foundry) Standard toolkit
3HAC 17542-1 3HAC 17594-1 The contents are defined in section Standard toolkit in the Product manual, reference information..
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Equipment, etc.
Note
Replacement, arm house unit
The procedure below details how to replace the 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!
Step
1. 2. 3. 4. 5. 6.
Action
Remove the wrist unit. Remove the motors for axes 4, 5 and 6. Remove the arm house unit. Fit the new arm house unit . Refit the wrist unit.
Info/Illustration
Detailed in section Removal of wrist unit on page 126. Detailed in section Removal of motor, axes 4, 5 and 6 on page 198. Detailed in section Removal of complete upper arm on page 119. Part no. is specified in Required equipment on page 133. Detailed in section Refitting of wrist unit on page 128.
Refit the motors for axes 4, 5 and 6. Detailed in sections Refitting of motor, axis 4 on page 200 Refitting of motor, axis 5 on page 203 Refitting of motor, axis 6 on page 206
7.
Calibration with the pendulum is detailed in the Calibration Pendulum Instruction , enclosed with the calibration toolkit. Other calibration is detailed in section Calibration on page 219.
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4.3.6 Replacement of mechanical stop, axis 4
Location of mechanical stop
The mechanical stop of axis 4 is located in the upper arm as shown 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
x
C
x
x-x
xx0300000176
A B C
Mechanical stop axis 4 Damper axis 4 Attachment screws, mech stop

Mechanical stop, axis 4 Damper Flange sealing Standard toolkit

3HAB 8856-1 3HAB 3760-1 1234 0011-116 3HAC 17594-1
Note
Loctite 574 The contents are defined in section Standard toolkit in the Product manual, reference information.. These procedures include references to the tools required.
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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 function Resetting the work area for an axisis used, or if the robot is jogged uncalibrated.
Removal, mechanical stop
The procedure below details how to remove the axis 4 mechanical stop from the manipulator.
Step
1. 2.
Action
Remove the mechanical stop by removing its attachment screws. Rotate axis 4 so that the damper is visible. Remove the damper.
Info/Illustration
Shown in the figure Location of mechanical stop on page 136. Shown in the figure Location of mechanical stop on page 136.
Refitting, mechanical stop
The procedure below details how to refit the axis 4 mechanical stop to the manipulator.
Step
1.
Action
Fit the damper to the axis 4.
Note/Illustration
Shown in the figure Location of mechanical stop on page 136. Part no. is specified in Required equipment on page 136. Art. no. is specified in Required equipment on page 136. Shown in the figure Location of mechanical stop on page 136. Part no. is specified in Required equipment on page 136. 4 pcs, M8x16. Tightening torque: 24 Nm.
2. 3.
Apply flange sealing to the stop. Fit the mechanical stop to the axis 4 with its attachment screws.
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4.3.7 Replacement of signal cabling, upper arm (option 042)
Location of signal cabling, upper arm
The signal cabling (option 042) runs along the upper arm as shown in the figure below.
D
xx03000000192
A B C D
Wrist bracket Upper arm bracket Front and rear cable holders Plastic hose
Required equipment Equipment, etc. Spare part no. Art. no. Note
Includes signal/power cabling, necessary brackets, holders etc. 3HAC 17594-1 The contents are defined in section Standard toolkit in the Product manual, reference information.. These procedures include references to the tools required. Customer connection axis 4 3HAC 8820-1
Standard toolkit
Removal, signal cabling upper arm
The procedure below details how to remove the signal cabling from the 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!
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- 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.
Step
1.
Action
Remove the wrist bracket and the upper arm bracket from the upper arm. Remove the front and rear cable holders from the tube shaft. Disconnect the connectors at the rear of the upper arm.
Info/Illustration
Shown in the figure Location of signal cabling, upper arm on page 138. Shown in the figure Location of signal cabling, upper arm on page 138.
2.
3.
Refitting, signal cabling upper arm
The procedure below details how to refit the signal cabling to the upper arm.
Step
1.
Action
Fit transparent protection tape to the narrow part of the tube shaft. Remove dirt and grease from the surface first! Move axis 4 to its calibration position (0). Refit the wrist bracket to the upper arm.
Note/Illustration
2. 3.
Location of the bracket is shown in the figure Location of signal cabling, upper arm on page 138.
xx0300000193
A: 2 pcs, M8x12.
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Step
4.
Action
Refit the upper arm bracket to the upper arm.
Note/Illustration
Location of the bracket is shown in the figure Location of signal cabling, upper arm on page 138.
xx0300000194
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. Complete the rotation. Note! Do not tighten the rear cable holder, leave it open! First fit the front cable holder around the tube 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.
B: 3pcs, M8x12.
6.
7.
xx0300000197
A: Plastic hose B: Cable holder
Also see the figure Location of signal cabling, upper arm on page 138. 8. Move axis 4 from one extreme limit to the other and back again.
Caution!
Check the cables during movement: the cables must not be fully extended! the cables and air hose must not touch any moving parts of the arm! the fixing rings must always slide smoothly with no excessive pulling!
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Step
9.
Action
Adjust the length of the cables by pushing and pulling the cables through the inner holders, which are still loose. Note! When axis 4 is moving, no stretching of the cables should be felt.
Note/Illustration
10. Tighten the holders by hand. Do not use tools. 11. Reconnect the connectors at the rear end of the upper arm. 12. Connect the air hose. 13. Secure the cables and air hose together with cable straps above the motors.
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4.3.8 Measuring the play, axis 5
General
After reassembly due to repair work or any other reason, the play in axis 5 and 6 must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 5 is detailed below.

Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information..
Measuring tool, play (IRB 4400/45, /60, /L30, /S) Measuring tool, play (IRB 4400/L10) Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
3HAC 1611-6 3HAB 6337-1 These procedures include references to the tools required.
Measurement, axis 5
The procedure below details how to measure the play of 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.
Step
1. 2.
Action
Move the robot to calibration position and turn the axis 4 90. Fit the measuring tool, play to the turning disk.
Info/Illustration
Art. no. is specified in Required equipment on page 142.
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Step
3.
Action
Apply load F in one direction, as shown in the figure to the right. Note! Different load and distances for the different robot versions, as specified to the right!
Info/Illustration
F
B C
A
xx0300000186
Values for robot version IRB 4400/45, /60, /L30, /S: A: Measuring tool, play B: 100mm C: 140mm F: 200N
Values for robot version IRB 4400/L10: A: Measuring tool, play 4. Remove the load and set the dial indicator to zero. B: 140mm C: 85mm F: 40N
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Step
5.
Action
Apply load F in the opposite direction, as shown in the figure to the right.
Info/Illustration
F
A
xx0300000187
Values for robot version IRB 4400/45, /60, /L30, /S: A: Measuring tool, play B: 100mm C: 140mm F: 200N
Values for robot version IRB 4400/L10: A: Measuring tool, play 6. B: 140mm C: 85mm F: 40N
Remove the load and measure the play by read- The maximum play allowed at ing the dial indicator. the given distance from the center of axis 5 is, for robot version IRB 4400/45, /60, /L30, / S: 0.20mm IRB 4400/L10: 0.08mm .
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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.

Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information..
Measuring tool, play (IRB 4400/45, /60, /L30, /S) Measuring tool, play (IRB 4400/L10) Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
3HAB 1611-6 3HAB 6337-1 These procedures include references to the tools required.
Measurement, axis 6
The procedure below details how to measure the play in 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.
Step
1.
Action
Fit the measuring tool, play to the turning disk.
Info/Illustration
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Step
2.
Action
Attach a weight (m) at a distance (B) from the wrist flange, in order to avoid the effects of play on axis 5. Note! Different weight and distance for the different robot versions, as specified to the right!
Info/Illustration
m A
xx0300000188
Values for robot version IRB 4400/ 45, /60, /L30, /S: A: Measuring tool, play B: 100mm m: 20 kg
Values for robot version IRB 4400/ L10: A: Measuring tool, play 3. Apply load F in one direction. Note! Different load and distances for the different robot versions, as specified to the right! B: 140mm m: 10 kg
F B C
A
xx0300000189
Values for robot version IRB 4400/ 45, /60, /L30, /S: A: Measuring tool, play B: 100mm C: 100mm F: 100N
Values for robot version IRB 4400/ L10: A: Measuring tool, play 4. Remove the load and set the dial indicator to zero. B: 100mm C: 150mm F: 40N
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Step
5.
Action
Apply load F in the opposite direction, as shown in the figure to the right.
Info/Illustration
A F
xx0300000190
Values for robot version IRB 4400/ 45, /60, /L30, /S: A: Measuring tool, play B: 100mm C: 100mm F: 100N
Values for robot version IRB 4400/ L10: A: Measuring tool, play 6. Remove the load and measure the play by reading the dial indicator. B: 100mm C: 150mm F: 40N
The maximum play allowed at the given distance (B) from the center of axis 6 is, for robot version IRB 4400/45, /60, /L30, /S: 0.15mm IRB 4400/L10: 0.2mm .
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4.4.1 Removal of lower arm
4.4: Lower arm 4.4.1 Removal of lower arm
Location of lower arm
The lower arm is located as shown 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 E F
A B C x x
D x-x
xx0300000141
A B C D 148
Lower arm Attachment screws and friction washers, lower arm Calibration plate, axis 2 Damper Revision 3HAC 022032-001
4 Repair
4.4.1 Removal of lower arm
E F
Parallel arm V-ring between lower arm and gearbox axis 3

Standard toolkit

3HAC 17594-1
Note
Removal, lower arm
The procedure below details how to remove the lower arm 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 lower arm weighs 68 kg! All lifting equipment used must be dimensioned accordingly!
Step
1. 2. 3. 4. 5.
Action
Remove the cabling down to axis 1. Remove the complete upper arm. Attach a crane to the lower arm and unload the weight. Remove the balancing device. Remove the parallel arm.
Info/Illustration
Detailed in section Removal of cable harness, axes 4-6 on page 105. Detailed in section Removal of complete upper arm on page 119.
Detailed in section Removal of balancing device on page 164. Detailed in section Removal of parallel arm /Removal of bearing on page 158. Shown in the figure Location of lower arm on page 148.
6. 7.
Remove the attachment screws and friction washers, lower arm. Remove the lower arm from the manipulator.
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4.4.2 Refitting of lower arm
Location of lower arm
The lower arm is located as shown 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 E F
A B C x x
D x-x
xx0300000141
A B C D E F
Lower arm Attachment screws and friction washers, lower arm Calibration plate, axis 2 Damper Parallel arm V-ring between lower arm and gearbox axis 3
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Lower arm 3HAC 5955-1 (IRB 4400/45, /60, /L10, /L30) Lower arm (IRB 4400FS) V-ring 3HAC 5956-1 3HAC 3773-11 2 pcs On both sides of the lower arm, in the frame. 3HAB 3537-1 3HAC 17594-1 Used to grease sealings and bearings. The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Grease Standard toolkit
Refitting, lower arm
The procedure below details how to refit the lower arm 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. Caution! The lower arm weighs 68 kg! All lifting equipment used must be dimensioned accordingly!
Step
1. 2.
Action
Info/Illustration
Move the damper and the calibration Part no. is specified in Required equipplate from the old to the new lower arm. ment on page 151. Check and grease both V-rings in the frame. Replace if damaged. Part no. is specified in Required equipment on page 151.
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Step
3.
Action
Lift the lower arm and lower it into mounting position. Make sure both V-rings stay seated properly! Refit the lower arm to the gearbox axis 2 with attachment screws and friction washers, lower arm. Grease the bearing seating of the parallel arm in the lower arm, to prevent clicking during operation. Refit the parallel arm. Refit the balancing device. Refit the upper arm. Refit the cabling. Recalibrate the robot!
Info/Illustration
4.
10 pcs, M16x55. Tightening torque: 260 Nm. Shown in the figure Location of lower arm on page 150.
5.
6. 7. 8. 9. 10.
Detailed in section Refitting of parallel arm /Refitting of bearing on page 161. Detailed in section Refitting of balancing device on page 168. Detailed in section Refitting of complete upper arm on page 122. Detailed in section Refitting of cable harness, axes 4-6 on page 109. Calibration with the pendulum is detailed in the Calibration Pendulum Instruction, enclosed with the calibration toolkit. Other calibration is detailed in section Calibration on page 219.
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4.4.3 Removal 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 the Foldout section in the Product manual, reference information!
F E C B D
A E C B D
X
F X-X
xx0300000117
A B C D E F G
Tie rod Attachment screw Washer O-ring Sealing, outside Spherical roller bearing Sealing, inside
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Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information. 2 pcs Used to pull out the tie rod alternately at the upper and lower end if the tie rod. These procedures include references to the tools required.
Puller tool
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.
Step
1. 2. 3. 4. 5.
Action
Lock the upper arm in a horizontal position with help of a crane or similar. Remove the two attachment screws . Remove the two washers, o-rings and sealings, outside from the tie rod. Insert a screw in each center, to be used as a support. Use two puller tools to pull out the tie rod, one at the upper and lower end. Pull alternately at the upper end and at the lower end with the puller tools! Remove the bearings if they are to be replaced.
Info/Illustration
Shown in the figure Location of tie rod on page 153. Shown in the figure Location of tie rod on page 153.
6.
The part no. for new bearings is specified in section Refitting of tie rod on page 155.
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4.4.4 Refitting 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 the Foldout section in the Product manual, reference information!
F E C B D
A E C B D
X
F X-X
xx0300000117
A B C D E F G
Tie rod Attachment screw Washer O-ring Sealing, outside Spherical roller bearing Sealing, inside

Washer

3HAB 3704-1
Note
Replace if damaged.
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Equipment, etc.
O-ring Sealing, outside Spherical roller bearing Sealing, inside Grease

3HAB 3772-23 3HAC 3297-1 3HAA 2167-11 3HAC 3990-11 3HAB 3537-1
Note
Used to lubricate the shaft on the manipulator where the tie rod is to be refitted. Loctite 243 The contents are defined in section Standard toolkit in the Product manual, reference information. Used to press in the spherical roller bearing. 2 pcs Used to press on the tie rod alternately at the upper and lower end of the tie rod. These procedures include references to the tools required.
Locking liquid Standard toolkit 3HAC 17594-1
Press tool Press tool, p-arm
3HAB 1598-1 3HAB 1529-1
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. Calibration Pendulum Instruction
Art. no. is specified in Document references in the Product manual, reference information.
Refitting, tie rod
The procedure below details how to refit the tie rod on to the manipulator. Warning! 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.
Step
1.
Action
Info/Illustration
If the bearings are to be replaced, fit new spheri- Part/ Art. no. is specified in cal roller bearings and new sealings, inside to Required equipment on page the tie rod. 155. Use the press tool. Lift the tie rod to its mounting site. Make sure the tie rod is refitted with the correct end up!
2.
156
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Step
3.
Action
Info/Illustration
Grease the shaft on the manipulator and refit the Art. no. is specified in Required tie rod on to the manipulator using two press equipment on page 155. tools for p-arm. Press alternately at the upper and lower end with the press tools! Fit the sealings, outside to the tie rod. Fit the o-rings to the tie rod. Refit the washers and attachment screws using locking liquid. Part no. is specified in Required equipment on page 155. Part no. is specified in Required equipment on page 155. Shown in the figure Location of tie rod on page 155. Locking liquid specified in Required equipment on page 155. Calibration with the pendulum is detailed in the Calibration Pendulum Instruction, enclosed with the calibration toolkit. Other calibration is detailed in section Calibration on page 219.
4. 5. 6.
7.
Recalibrate the robot.
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4.4.5 Removal of parallel arm /Removal of bearing
Location of parallel arm
The parallel arm is located on the manipulator, as shown in the figure below. 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!
D B
xx0300000128
A B C D E F
Parallel arm Attachment screw Washer V-ring on parallel arm Bearing Sealing
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Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information. Used to lift the parallel arm. These procedures include references to the tools required.
Lifting tool Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
3HAB 1412-1
Removal, parallel arm/bearing
The procedure below details how to remove the parallel arm from the manipulator during 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!
Step
1. 2. 3.
Action
Remove the tie rod. Fit the lifting tool to the parallel arm. Unload the arm with a crane. Loosen the attachment screws (A) so that the cabling can be moved slightly.
Info/Illustration
Detailed in Removal of tie rod on page 153. Art. no. is specified in Required equipment on page 159.
xx0300000127
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Step
4.
Action
Remove the 10 attachment screws and the washer that holds the parallel arm to gearbox axis 3. Lift away the parallel arm from the manipulator. If they are to be replaced, remove the bearing and sealings from the parallel arm.
Info/Illustration
5. 6.
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4.4.6 Refitting of parallel arm /Refitting of bearing
Location of parallel arm
The parallel arm is located on the manipulator, as shown in the figure below. 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!
D B
xx0300000128
A B C D E F
Parallel arm Attachment screw Washer V-ring on parallel arm Bearing Sealing
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V-ring Groove ball bearing Sealing ring Grease Standard toolkit

3HAC 3732-11 3HAC 10905-1 3HAB 3749-1 3HAB 3537-1 3HAC 17594-1
Note
Used to lubricate the bearings and sealings. The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Lifting tool Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below. Calibration Pendulum Instruction
3HAB 1412-1
Refitting, parallel arm/bearing
The procedure below details how to refit the parallel arm on to the manipulator during repair 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!
Step
1. 2.
Action
Fit the new V-ring to the parallel arm.
Info/Illustration
If the bearing is to be changed: Part no. is specified in Required 1. Heat the new groove ball bearing to equipment on page 162. 170C. 2. Fit the bearing to the parallel arm. If the old bearing is kept: 1. Grease the bearing.
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Step
2. 3.
Action
Fit the sealing ring to the bearing.
Info/Illustration
Refit the washer and the 10 attachment 10 pcs, M16x80, 12.9 quality screws that hold the parallel arm to the gear- UNBRAKO. Tightening torque: 260 box unit. Nm. Reused screws may be used, providing they are lubricated as detailed in section Screw Joints in the Product manual, reference information, before fitting. Move the upper arm to a horizontal position Detailed in section Refitting of tie rod with a crane (if not already positioned hori- on page 155. zontal) and refit the tie rod. Reposition the cabling and tighten the cable attachment screws (A).
4.
5.
xx0300000127
6.
Calibration with the pendulum is detailed in section Calibration Pendulum Instruction, enclosed with the calibration toolkit. Other calibration is detailed in section Calibration on page 219.
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4.5.1 Removal of balancing device
4.5: Frame and base 4.5.1 Removal of balancing device
Location of balancing device
The balancing device is located as shown in the figure below. A more detailed view of the component and its position may be found in the Foldout section!
A B D
F
xx0300000100
A B C D E F G
Balancing device Bracket Attachment screws, bracket (M12x50) Press out hole Front screws Fork End part of shaft
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Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit . M10x40H H= threaded to the head. Used to unload the balancing device before removal. These procedures include references to the tools required.
Securing front screws
Removal, balancing device
The procedure below details how to remove the balancing 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!
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Step
1.
Action
Move the manipulator to the calibration position, as shown in the figure to the right.
Info/Illustration
xx0300000088
2. Remove the two securing screws (A), located at the fork of the balancing device.
A: Approximately 2
xx0300000089
The fork is shown in the figure Location of balancing device on page 164.
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Step
3.
Action
Unload the balancing device by replacing the two front screws (A) with two securing front screws . Unload the device level by fastening the securing screws parallel with each other.
Info/Illustration
xx0300000095
Dimension specified in Required equipment on page 165! 4. 5. Check that the piston is unloaded by moving it manually. Remove the four attachment screws, Shown in the figure Location of balbracket from the bracket at the right side of ancing device on page 164! the balancing device (A), seen from above.
A
xx0300000098
6.
Remove the bracket from the frame by Shown in the figure Location of balpressing it out using a M10x30 screw in the ancing device on page 164! press out hole . Remove the balancing device by pushing it to the side. Note! The balancing device weighs 50 kg!
7.
xx0300000099
8.
If the balancing device is to be replaced with a new device, the bracket on the right side must be removed and fitted to the new device.
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4.5.2 Refitting of balancing device
Location of balancing device
The balancing device is located as shown in the figure below. A more detailed view of the component and its position may be found in the Foldout section!
A B D
F
xx0300000100
A B C D E F G
Balancing device Bracket Attachment screws, bracket (M12x50) Press out hole Front screws Fork End part of shaft
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Balancing device (IRB 4400/45, IRB 4400/60, IRB 4400L/ 10, IRB 4400L/30)

3HAC 15083-1
Note
Includes balancing device 3HAC 3702-1 Includes cylindrical roller bearing 3HAC 4334-2 Includes front screws 3HAC 6456-1 Includes balancing device 3HAC 3738-1 Includes cylindrical roller bearing 3HAC 4334-2 Includes front screws 3HAC 6456-1
Balancing device (IRB 4400FS)
3HAC 15083-2
Sealing ring with dust lip Grease
3HAB 3701-26 3HAC 3537-1 Udes to lubricate: the bearings at the balancing device brackets (min. 500 ml in each bearing) the sealing at the balancing device brackets the bearing at the balancing device fork.
Nipple
Used to lubricate the bearing at the balancing device fork. The lubrication hole is dimensioned M10. 3HAC 17594-1 3HAC 5465-1 The contents are defined in section Standard toolkit . Used to fit the cylindrical roller bearings and the sealings into the brackets. These procedures include references to the tools required.
Standard toolkit Press tool, bearing
Refitting, balancing device
The procedure below details how to refit the balancing 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!
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- 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!
Step
1.
Action
Info/Illustration
Fit the cylindrical roller bearings and sealings Part no. is specified in Required to the balancing device and brackets if equipment on page 169! the balancing device is a new spare part the old bearings/sealings are damaged.
The procedure is detailed in Fitting of cylindrical roller bearing on page 172. 2. Lift the balancing device to its mounting position. If the balancing device is a new spare part, it must be unloaded as described in Removal, balancing device on page 165. Note! The balancing device weighs 50 kg! Fit the balancing device to the left bracket and put the fork into correct position. Refit the right bracket with attachment screws, bracket . Shown in the figure Location of balancing device on page 168. Shown in the figure Location of balancing device on page 168. 4 pcs: M12x50, tightening torque: 82 Nm. 2 pcs; MC6S M10x12 8.8 fzb. Shown in the figure Location of balancing device on page 168.
3. 4.
5.
Refit the original protection screws in the press out holes in both the brackets.
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Step
6.
Action
Lubricate the bearing at the fork: 1. Remove the two stop screws. 2. Fill with grease through one of the lubrication holes, until excessive grease is forced out through the second hole. Use a nipple! 3. Refit the two stop screws.
Info/Illustration
xx0300000089
4.
A: Securing screws (2 pcs) B: Stop screws, M10 x 40 (2 pcs)
Before restoring the balancing device, check The fork is shown in the figure Locathat: tion of balancing device on page 168. the fork is in position the fork does not cover the lubrication holes of the shaft!
5.
Restore the balancing device by removing 2 pcs; MC6S M10x12 8.8 fzb. the replacement front screws (A) and refitting the original protection front screws.
xx0300000095
6.
Refit the fork to the shaft in the lower arm, by refitting the two securing screws (A) at the fork of the balancing device, shown in figure xx0300000089. Make sure that the fork does not cover the lubrication holes of the shaft!
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Fitting of cylindrical roller bearing
The procedure below details how to fit the cylindrical roller bearings onto the balancing device shaft and into the frame brackets.
Step
1. 2. 3. 4.
Action
Fit the inner ring of the bearing onto both end parts of the balancing devices shaft.
Note/Illustration
Shown in the figure Location of balancing device on page 168.
Fit the outer ring of the bearing into both brackets Art. no. is specified in Required with the press tool, bearing. equipment on page 169. Fit the sealing ring with dust lip with the same, but Part no. is specified in Required turned, press tool, bearing. equipment on page 169. Lubricate the bearing and the sealing with grease. Art. no. and amount specified in Required equipment on page 169.
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4.5.3 Replacement of serial measurement unit
Location of serial measurement unit
The serial measurement unit is located inside the base of the manipulator, behind the rear cover, as shown in the figure below.
xx0300000106
Rear cover plate
Different versions, serial measurement unit
There are two versions of the serial measurement unit. They are compatible but designed differently, as shown in the figure below. Note! The battery pack is not compatible between the versions!
A (1)
D (2)
AT T E NT ION
Obs er ve pr ecautions f handling E le ctrostatic s ensitive devices or
D C
xx0300000105
(1) (2) A B C D E
Old version of serial measurement unit New version of serial measurement unit R2.SMB R2.FB4-6 R2.FB1-3 Fastening plate Battery pack
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Includes fastening plate 3HAC 3367-1 Serial measurement unit, old 3HAC 14505-1 version Battery pack, old version Serial measurement unit, new version Battery pack, new version Fastening plate, new version Standard toolkit 4944 026-4 3HAC 16014-1 3HAC 16831-1 3HAC 17395-1 3HAC 17594-1 The contents are defined in section Standard toolkit . These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Repair Manual, part 2 (Circuit Diagram)
Art. no. is specified in section Document references .
Removal, serial measurement unit
The procedure below details how to remove the serial 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.
Step
1.
Action
Remove the rear cover plate from the base.
Note/Illustration
Shown in the figure Location of serial measurement unit on page 173.
2. 3. 4.
Cut all the straps. Unscrew the nuts that attaches the serial measurement unit inside the base. Remove the serial measurement unit.
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Step
5.
Action
Remove the connectors from the board.
Note/Illustration
The connectors are shown in the figure Different versions, serial measurement unit on page 173.
Refitting, serial measurement unit
The procedure below details how to refit the complete serial 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.
Step
1.
Action
Refit the connectors to the serial measurement unit .
Note/Illustration
Art. no. is specified in Required equipment on page 174. The connectors are shown in the figure Different versions, serial measurement unit on page 173.
2. 3. 4. 5.
Refit the serial measurement unit inside the base using nuts. Strap the cables. Refit the rear cover plate on the base. Recalibrate the robot! Shown in the figure Location of serial measurement unit on page 173. Detailed in section Calibration on page 219.
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4.5.4 Replacement of pushbutton unit for brake release
Location of pushbutton unit
The pushbutton unit for brake release is located in the base of the robot, as shown in the figure below. A more detailed view of the component and its position may be found in the Foldout section!
xx0300000106
Rear cover plate
Connectors on pushbutton unit
The connectors X8, X9 and X10 are placed on the pushbutton unit as shown in the figure below.
X8
xx0300000201
X9
X10

Pushbutton unit Standard toolkit Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below. Calibration Pendulum Instruction

3HAC 0017-1 3HAC 17594-1
Note
The contents are defined in section Standard toolkit. These procedures include references to the tools required.
Art. no. is specified in section Document references .
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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, pushbutton unit
The procedure below details how to remove the pushbutton unit from the manipulator.
Step
1.
Action
Secure the manipulator by moving... the lower arm to one of its end positions the upper arm to its end position. Remove the rear cover plate. Remove the connectors X8, X9 and X10 from the pushbutton unit. Remove the pushbutton unit by removing its attachment screws.
Info/Illustration
2. 3. 4.
Shown in the figure Location of pushbutton unit on page 176. Shown in the figure Connectors on pushbutton unit on page 176.
Refitting of pushbutton unit
The procedure below details how to refit the pushbutton unit to the manipulator.
Step
1. 2. 3. 4.
Action
Refit the new pushbutton unit with its attachment screws. Refit the connectors X8, X9 and X10 to the pushbutton unit. Refit the rear cover plate to the base of the manipulator. Recalibrate the robot!
Note/Illustration
Part no. is specified in Required equipment on page 176. Shown in the figure Connectors on pushbutton unit on page 176. Shown in the figure Location of pushbutton unit on page 176. Calibration with the pendulum is detailed in the Calibration Pendulum Instruction, enclosed with the calibration toolkit. Other calibration is detailed in section Calibration on page 219.
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4.5.5 Replacement of mechanical stop pin, axis 1
Location of mechanical stop pin
The mechanical stop pin on axis 1 is located on the frame as shown in the figure below. A more detailed view of the component and its position may be found in the Foldout section!
A
xx0300000182
A B
Mechanical stop pin, axis 1 Set screw

Mechanical stop, axis 1 Standard toolkit

3HAB 3647-1 3HAC 17594-1
Note
The contents are defined in section Standard toolkit . These procedures include references to the tools required.
Replacement, mechanical stop pin
The procedure below details how to replace the mechanical stop pin on axis 1.
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Warning! If the mechanical stop has been deformed after a hard collision, it must be replaced!
Step
1. 2. 3.
Action
Remove the set screw .
Info/Illustration
Shown in the figure in Location of mechanical stop pin on page 178.
Remove the old mechanical stop pin . Shown in the figure in Location of mechanical stop pin on page 178. Refit the new mechanical stop with the Part no. is specified in Required equipset screw. ment on page 178. M10x12
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4.6.1 Removal of motor, axis 1
4.6: Motors 4.6.1 Removal of motor, axis 1
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 B C
Motor, axis 1 Connection box with cover Attachment screws and washers

Standard toolkit

3HAC 17594-1
Note
See chapter Circuit diagrams in the Product manual, reference information
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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.
Step
1. 2. 3. 4.
Action
Remove the cover of the connection box . Disconnect all the connectors in the motor. Remove the connection box .
Info/Illustration
Shown in the figure Location of motor on page 180. Shown in the figure Location of motor on page 180.
Remove the attachment screws and washers of Shown in the figure Location of the motor. motor on page 180. Note the position of the motor label before removing the motor! The motor must be mounted back at the same position! Remove the motor.
5.
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4.6.2 Refitting of motor, axis 1
Location of motor
A
xx0300000154
A B C
Motor, axis 1 Connection box with cover Attachment screws and washers
Includes motor pinion. Includes motor pinion. Motor unit, axis 1 3HAC 5952-1 (IRB 4400/45, /60, /L10, /L30) Motor unit, axis 1 (IRB 4400/S) O-ring, motor Flange sealing Gasket 3HAC 4432-1 3HAC 9841-1 2152 0431-11 1234 0011-116 Loctite 574 Between the motor and the connection box. Replace if damaged.
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Equipment, etc.
Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information. 24 VDC, 1.5 A Used in order to release the brakes.
Power supply
Measuring tool Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram
3HAB 7887-1 or Choose one of the tools. 3HAB 1408-1 These procedures include references to the tools required.
See chapter Circuit diagrams in the Product manual, reference information. Art. no. is specified in section Document references in the Product manual, reference information.
Refitting, motor axis 1
The procedure below details how to refit 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. Note! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!
Step
1.
Action
Check that the assembly surfaces are clean from paint, lubricant etc. Make sure that the motor and the gearbox are not damaged or scratched. Fit the o-ring to the new motor unit.
Info/Illustration
2.
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Step
3.
Action
Info/Illustration
Release the brake of the motor by connecting the Connect to connector R3.MP1 24 VDC power supply. +24V: pin 7 0V: pin 8. Apply flange sealing to the motor flange. Place the new motor in the gearbox. Do not damage the pinion and the gear wheel! Note the position of the motor! The motor label should be mounted in the same position as it had before the removal. Fit the upper and lower screws (A, B) and tighten until there is no space between the motor flange and the gearbox. There should be a big backlash between the motor pinion and the gear. Art. no. is specified in Required equipment on page 182.
4. 5.
6.
C
xx0300000155
7.
A: Lower screw B: Upper screw C: Pushing direction
Adjustment detailed in section Adjustment of motors, axes 1-3 on page 196.

Note!
Adjust the motor before continuing the refitting procedure! 8. 9. Fit the other two attachment screws and washers. Check the oil level. Fill with oil if necessary. Total 4 pcs, M10x30. Tightening torque: 60 Nm. Detailed in section Inspection of oil levels on page 80. Part no. is specified in Required equipment on page 182.
10. Refit the connection box. Replace the gaskets if they are damaged. 11. Reconnect all the connectors. 12. Refit the cover of the connection box.
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Step
Action
Info/Illustration
Calibration with the pendulum is detailed in the Calibration Pendulum Instruction, enclosed with the calibration toolkit. Other calibration is detailed in section Calibration on page 219.
13. Recalibrate the robot!
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Location of motor
A B
C
xx0300000159
A B C
Motor, axis 2 Connection box Attachment screws and washers

Standard toolkit

3HAC 17594-1
Note
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram
See the chapter Circuit diagrams in the Product manual, reference information
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Removal, motor axis 2
The procedure below details how to remove the motor, axis 2.
Step
1.
Action
Info/Illustration
Danger!
Secure the arm system before removing the motor! The brake is located in the motor and is therefore released when the motor is removed. 2. 3. 4. 5. Remove the cover of the connection box. Disconnect all the connectors in the motor. Remove the connection box. Note the position of the motor label before removing it. The motor must be mounted in the same position. Remove the attachment screws and washers of the motor. Note! Oil will start to run out when removing the motor! Remove the motor. Shown in the figure Location of motor on page 186. Shown in the figure Location of motor on page 186.
6.
7.
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Location of motor
A B
C
xx0300000159
A B C
Motor, axis 2 Connection box Attachment screws and washers

Motor unit, axis 2 O-ring Flange sealing Standard toolkit

3HAC 5954-1 2152 0431-11 1234 0011-116 3HAC 17594-1
Note
Includes pinion. Loctite 574 The contents are defined in section Standard toolkit in the Product manual, reference information. 24 VDC, 1.5 A Used in order to release the brakes.
Power supply
Measuring tool
3HAB 7887-1 3HAB 1408-1
Choose one of the two tools.
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Equipment, etc.
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. Circuit Diagram
Note
See the chapter Circuit diagram in the Product manual, reference information Art. no. is specified in section Document references in the Product manual, reference information.
Step
1.
Action
Check that the assembly surfaces are clean from paint, lubricant etc. Make sure that the motor and the gearbox are not damaged or scratched. Mount the o-ring to the new motor unit.
Info/Illustration
2. 3.
Release the brake of the motor by connecting the Connect to connector R3.MP2 24 VDC power supply. +24V: pin 7 0V: pin 8. Apply flange sealing to the motor flange. Place the new motor in the gearbox. Do not damage the pinion or the gear wheel! Note the position of the motor! The motor label should be mounted in the same position as it had before the removal. Art. no. is specified in Required equipment on page 188.
4. 5.
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Step
6.
Action
Fit the upper and lower screws (A, B) and tighten until there is no space between the motor flange and the gearbox. There should be a big backlash between the motor pinion and the gear.
Info/Illustration
A B
C
xx0300000160
7.
A: Upper screw B: Lower screw C: Pushing direction
Adjustment is detailed in section Adjustment of motors, axes 1-3 on page 196.

Note!
Adjust the motor before continuing the refitting procedure! 8. Fit the other two attachment screws and washers. Shown in the figure Location of motor on page 188. 2 pcs: M10x70, 2 pcs: M10x30. Tightening torque: 60 Nm. Detailed in section Oil in gearbox unit, axis 1-2-3 on page 79. Shown in the figure Location of motor on page 188.
9. 10. 11. 12. 13.
Refill with oil. Refit the connection box. Reconnect the connectors. Refit the cover of the connection box. Recalibrate the robot!
Calibration with the Pendulum is detailed in the Calibration Pendulum Instruction, enclosed with the calibration toolkit. Other calibration is detailed in section Calibration on page 219.
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Location of motor
A B
C
xx0300000163
A B C
Motor, axis 3 Connection box Attachment screws and washers, motor

Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
See the chapter Circuit diagrams in the Product manual, reference information.
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Removal, motor axis 3
The procedure below details how to remove the motor, axis 3.
Step
1.
Action
Info/Illustration
Danger!
Secure the upper arm system before removing the motor from axis 3! The brake is located in the motor and is therefore released when the motor is removed. 2. 3. 4. Remove the cover from the connection box. Disconnect all the connectors in the motor. Remove the connection box from the motor. Shown in the figure Location of motor on page 191.
5.
Note the position of the motor label before removing it! The motor must be mounted in the same position. Remove the attachment screws and washers, Shown in the figure motor. Location of motor on Note! Oil will start to run out when removing the page 191. motor! Remove the motor.
6.
7.
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Location of motor
A B
C
xx0300000163
A B C
Motor, axis 3 Connection box Attachment screws and washers, motor

Motor unit, axis 3 O-ring Flange sealing Standard toolkit
Spare part no.

3HAC 5954-1 3HAC 2152 0431-11
Art. no.
Note
Includes pinion.
1234 0011-116 3HAC 17594-1
Loctite 574 The contents are defined in section Standard toolkit in the Product manual, reference information! 24 VDC, 1.5 A To be used for releasing the brakes.
Power supply
Measuring tool
3HAB 7887-1 or Choose one of the two tools. 3HAB 1408-1
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Equipment, etc.
Spare part no.
Art. no.
Note
See the chapter Circuit diagrams in the Product manual, reference information. Art. no. is specified in section Document references in the Product manual, reference information.
Step
1.
Action
Check that the assembly surfaces are clean from paint, lubricant etc. Make sure that the motor and the gearbox are not damaged or scratched. Fit the o-ring to the new motor unit. Release the brake of the motor by connecting the 24 VDC power supply.
Info/Illustration
2. 3.
Part no. is specified in Required equipment on page 193. Connect to connector R3.MP3 +24V: pin 7 0V: pin 8. Art. no. is specified in Required equipment on page 193.
4. 5.
Apply flange sealing to the motor flange. Place the new motor in the gearbox. Do not damage the pinion and the gear wheel! Note the position of the motor! The motor label should be mounted in the same position as it had before the removal.
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Step
6.
Action
Info/Illustration
Fit the upper and lower screws (A, B) and tighten until there is no space between the motor flange and the gearbox. There should be a big backlash between A the motor pinion and the gear.
C
xx0300000160
Motor, axis 2, is shown in the figure! A: Upper screw 7. B: Lower screw C: Pushing direction
Adjustment is detailed in section Adjustment of motors, axes 1-3 on page 196.

Note!
Adjust the motor before continuing the refitting procedure! 8. Fit the other two attachment screws and washers, motor. Shown in the figure Location of motor on page 193. M10x70, M10x30. Tightening torque: 60 Nm. Detailed in the Maintenance Manual . Shown in the figure Location of motor on page 193.
9. 10. 11. 12. 13.
Refill with oil. Refit the connection box. Reconnect the connectors. Refit the cover of the connection box. Recalibrate the robot!
Calibration with the Pendulum is detailed in the Calibration Pendulum Instruction, enclosed with the calibration toolkit. Other calibration is detailed in section Calibration on page 219.
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4.6.7 Adjustment of motors, axes 1-3
General
This section details how to adjust the motors during refitting. It applies to the motors in axes 1, 2 and 3 and is a complement to the refitting instructions found in sections
Refitting of motor, axis 1 on page 182 Refitting of motor, axis 2 on page 188 Refitting of motor, axis 3 on page 193.

Standard toolkit

3HAC 17594-1
Note
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. 24 VDC, 1.5 A For releasing the brakes. These procedures include references to the tools required.
Power supply Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below. Circuit Diagram
See chapter Circuit diagrams in the Product manual.
Adjustment
The procedure below details how to adjust the motors during refitting.
Step
1. 2. 3.
Action
Lock the motor brake before mounting the adjustment tool. Fit the measuring tool to the motor axis.
Info/Illustration
Release the brake of the current motor Axis 1 motor: connect to connector R3.MP1 by connecting the 24VDC supply. +24V: pin 7 0V: pin 8. Axis 2 motor: connect to connector R3.MP2 +24V: pin 7 0V: pin 8. Axis 3 motor: connect to connector R3.MP3 +24V: pin 7 0V: pin 8.
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Step
4.
Action
Rotate the motor shaft with the measuring tool. Measure the torque in both directions with a spring balance. A normal torque is 0.6-0.8 Nm (=6-8 N on radius 100 mm). Torques higher than 0.8 Nm are not allowed, as they will reduce the lifetime of the motor and gear. Loosen the lower and upper screws until the motor can be moved sideways by hand. Note! The brake must be released in the motor. Push the motor with one hand against the gear and tighten the two screws with the other hand. Measure the torque with the motor shaft in different positions. The torque should be max. 0.1 Nm (on radius 50 mm) more than measured before. If the torque is more, slightly loosen the screws a little and carefully knock the motor in the opposite direction then measure the torque again.
Info/Illustration
5.
6.
7.
The brake disc is mounted on the motor shaft with a type of splined coupling. Between the splines there is a narrow backlash. Note! There should always be a backlash, but it should be as minimal as possible.
1)
Check that the backlash is very limited, by moving the tool back and forward in small movements. When turning the motor shaft, a ticktack sound can be heard from the brake disc 1) . This should not be mixed up with the backlash. The difficult part is to find the motor position where the torque just starts to increase. 8. 9. Remove the measuring tool. Disconnect the brake release voltage. Refitting, motor axis 1 on page 183 Refitting, motor axis 2 on page 189 Refitting, motor axis 3 on page 194
10. Continue refitting the motor.
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4.6.8 Removal of motor, axes 4, 5 and 6
Location of motors
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
x x
B E C
x-x
xx0300000164
A B C D E
Motor unit, axis 4 Motor unit, axis 5 Motor unit, axis 6 Attachment screws and washers, motor Connection box

Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, refernce information. These procedures include references to the tools required.
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Equipment, etc.
Circuit Diagram
Note
Art. no. is specified in section Document references in the Product manual, refernce information.
Removal, motor axes 4, 5 and 6
The procedure below details how to remove the motors of axes 4, 5 and 6.
Step
1.
Action
Info/Illustration
Danger!
Secure the arm system before removing any motor! The brake is located in the motor and is therefore released when the motor is removed! 2. Drain the oil from the gearbox. Draining is detailed in section: Oil change, gearbox axis 4 on page 84 Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10) on page 86 Oil change, gearbox axis 5 and 6 (IRB 4400/ L10 only) on page 89.
3. 4. 5. 6.
Remove the cover of the connection box. Disconnect all the connectors in the connection box. Remove the connection box. Note the position of the motor before removing it. The motor must be mounted back at the same position. Remove the attachment screws and washers, motor. Remove the motor. Shown in the figure Location of motors on page 198. Shown in the figure Location of motors on page 198.
7. 8.
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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
x x
B E C
x-x
xx0300000164
A B C D E

Motor unit, axis 4 O-ring Gasket

3HAC 10603-1 2152 2012-426 3HAC 3676-1
Note
Includes pinion. 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.
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Equipment, etc.
Measuring tool Power supply

3HAB 1409-1
Note
24VDC, 1.5A Used to release the brake of the motor. These procedures include references to the tools required.
See the chapter Circuit diagrams in the Product manual, refernce information. Art. no. is specified in section Document references in the Product manual, refernce information.
Step
1.
Action
Check that the assembly surfaces are clean from paint, lubricant etc. Make sure that the motor and the gearbox are not damaged or scratched. Fit the o-ring to the new motor unit. Fit the measuring tool to the rear of the motor. Release the brake of the motor by connecting the 24 VDC power supply.
Info/Illustration
2. 3. 4.
Part no. is specified in Required equipment on page 200. Art. no. is specified in Required equipment on page 200. Connect to connector R3.MP4 +24V: pin 7 0V: pin 8.
5.
Place the new motor unit in the gearbox. Do not damage the pinion or the gear wheel.
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4 Repair
Step
6.
Action
Find the position with the least play by turning the motor shaft 10 turns, noting changes in play as you turn the motor. Push the motor in a radial direction so that the play is minimal within one motor turn without the gear "chewing". Refit the motor with its attachment screws and washers, motor. Refill with oil, if drained.
Info/Illustration
7.
8.
Shown in the figure Location of motor on page 200. 4 pcs, M6x25. Tightening torque: 15 Nm. Detailed in section Oil change, gearbox axis 4 on page 84.
9.
10. Check the position of the three gaskets, Part no. is specified in Required equiplocated between the motors and the con- ment on page 200. nection box. Replace them if damaged. 11. Refit the connection box. Make sure the gaskets are seated properly! 12. Reconnect all the connectors. 13. Refit the cover to the connection box. 14. Recalibrate the robot! Calibration with the pendulum is detailed in Pendulum Calibration Instruction, enclosed with the calibration toolkit. Other calibration is detailed in section Calibration on page 219. Shown in the figure Location of motor on page 200.
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Location of motor
D
x x
B E C
x-x
xx0300000164
A B C D E
Includes pinion. Motor unit, axis 5 3HAC 10603-1 (IRB 4400/45, /60, /L30, /S) Motor unit, axis 5 (IRB 4400/L10) O-ring Gasket 3HAC 10605-1 2152 2012-426 3HAC 3676-1 3 pcs Between the motor and the connection box. Replace if damaged.
Includes pinion.
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Equipment, etc.
Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, refernce information. 24VDC, 1.5A 2 pcs, used to release the brakes in the motors for axes 4 and 5. These procedures include references to the tools required.
3HAB 1409-1
See chapter Circuit diagrams in the Product manual, refernce information. Art. no. is specified in section Document references in the Product manual, refernce information.
The procedure below details how to refit the axis 5 motor.
Step
1.
Action
Check that the assembly surfaces are clean from paint, lubricant etc. Make sure that the motor and the gearbox are not damaged or scratched. Fit the o-ring into the new motor. Fit the measuring tool to the rear of the motor.
Info/Illustration
2. 3.
Part no. is specified in Required equipment on page 203. Art. no. is specified in Required equipment on page 203.
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Step
4.
Action
Info/Illustration
Release the brakes in the motors for axes 4 and Connect to connector R3.MP4/ 5, by connecting the 24 VDC power supply. MP5 +24V: pin 7 0V: pin 8. Place the new motor unit in the gearbox. Do not damage the pinion or the gear wheel. Find the position of least play by turning the outgoing shaft for axis 4 in intervals of 90, one turn in all, to locate the area where the play for the motor axis 5 is the smallest. Turn the motor for axis 5 one full turn at a time, five turns in all. Find the smallest play within this range. Push the motor in a radial direction so that the play is minimal within one motor turn without the gear "chewing". Refit the motor with its attachment screws and washers, motor. Shown in the figure Location of motor on page 203. 4 pcs, M6x25. Tightening torque: 15 Nm. Detailed in sections Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10) on page 86 Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) on page 89.
5. 6.
7.
8.
9.
10.
Refill with oil, if drained.
11.
Check the position of the three gaskets , located Part no. is specified in Required between the motors and the connection box. equipment on page 203. Replace them if damaged. Refit the connection box. Make sure the gaskets are seated properly! Reconnect all the connectors. Refit the cover on the connection box. Recalibrate the robot! Calibration with the pendulum is detailed in the Calibration Pendulum Instruction, enclosed with the calibration toolkit. Other calibration is detailed in the section Calibration on page 219. Shown in the figure Location of motor on page 203.
12. 13. 14. 15.
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Location of motor
D
x x
B E C
x-x
xx0300000164
A B C D E
Includes pinion. Includes pinion. Motor unit, axis 6 3HAC 10604-1 (IRB 4400/45, /60, /L30, /S) Motor unit, axis 6 (IRB 4400/L10) O-ring Gasket 3HAC 10605-1 2152 2012-426 3HAC 3676-1 3 pcs Between the motors and the connection box. Replace if damaged.
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Equipment, etc.
Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information. 24VDC, 1.5A 3 pcs, used to release the brakes in the motors for axes 4, 5 and 6. These procedures include references to the tools required.
3HAB 1409-1
Art. no. is specified in section Document references in the Product manual, reference information. Art. no. is specified in section Document references in the Product manual, refernce information.
The procedure below details how to refit the axis 6 motor.
Step
1.
Action
Check that the assembly surfaces are clean from paint, lubricate etc. Make sure that the motor and the gearbox are not damaged or scratched. Fit the o-ring to the new motor unit . Fit the measuring tool at the rear of the motor.
Info/Illustration
2. 3.
Part no. is specified in Required equipment on page 206. Art. no. is specified in Required equipment on page 206.
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Step
4.
Action
Release the brakes in the motors for axes 4, 5 and 6, by connecting the 24 VDC power supply. Place the new motor unit in the gearbox. Do not damage the pinion or the gear wheel! Find the position of least play by turning the outgoing shaft for axis 4 in intervals of 90, one turn in all, to locate the area where the play for the axis 6 motor is the smallest. Turn the motor for axis 5 one full turn at a time, five turns in all. Find the least play for axis 6 within this range. Turn the motor for axis 6 one full turn at a time, three turns in all. Find the least play for axis 6 within this range. Push the motor in a radial direction so that the play is minimal within one motor turn without the gear "chewing".
Info/Illustration
Connect to connector R3.MP4/MP5/MP6 +24V: pin 7 0V: pin 8.
5.
6.
7.
8.
9.
10. Refit the motor with its attachment screws and washers, motor.
Shown in the figure Location of motor on page 206. 4 pcs, M6 x 25. Tightening torque: 15 Nm. Detailed in sections Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10) on page 86 Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) on page 89. Part no. is specified in Required equipment on page 206.
11. Refill with oil, if drained.
12. Check the position of the three gaskets , located between the motors and the connection box. Replace them if damaged.
13. Refit the connection box . Shown in the figure Location of motor on Make sure the gaskets are seated properly! page 206. 14. Reconnect all the connectors. 15. Refit the cover on the connection box. 16. Recalibrate the robot! Calibration with the pendulum is detailed in Calibration Pendulum Instruction , enclosed with the calibration toolkit. Other calibration is detailed in section Calibration on page 219.
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4.7.1 Removal of gearbox unit, axes 1-2-3
4.7: Gearboxes 4.7.1 Removal of gearbox unit, axes 1-2-3
General
The gearboxes of axes 1-2-3 are handled as one complete unit. Except for the gearboxes, the spare part also includes motor units and lubricating oil for the axes 1, 2 and 3.
Location of gearbox unit
The gearbox unit, axes 1-2-3, is shown in the figure below. A more detailed view of the component and its position may be found in the Foldout section!
C
xx0300000174
A B C D
Gearbox unit axes 1-3, spare part Bottom plate Attachment screws and washers, gearbox unit Sealing
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Standard toolkit

3HAC 17594-1
Note
The contents are defined in section Standard toolkit in the Product manual, reference information! Lifting capacity: 500 kg. These procedures include references to the tools required.
Lifting slings with hoisting block Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Removal, gearbox unit
The procedure below details how to remove the gearbox unit, axis 1-2-3, including the 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 accordingly! Caution! The base weighs 130 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Remove the cable harness and serial measuring board.
Info/Illustration
Detailed in sections Removal of cable harness, axes 1-3 on page 98, Removal of cable harness, axes 4-6 on page 105and Replacement of serial measurement unit on page 173. Detailed in section Removal of tie rod on page 153. Detailed in section Removal of parallel arm /Removal of bearing on page 158. Detailed in section Removal of complete arm system on page 114.
2. 3. 4. 5.
Remove the tie rod. Remove the parallel arm. Remove the complete arm system. Unfasten the manipulator from the foundation.
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Step
6.
Action
Fit and secure straps (A) around the rear part of the gearbox unit, as shown in the figure to the right. Attach the straps to lifting slings with a hoisting block. Fit and secure hooks to the lifting lugs (B). Use the same crane for both attachment points.
Info/Illustration
xx0300000172
7.
Lift the gearbox unit together with the base and use the hoisting block to tip the complete assembly forward 90. Place the assembly on a level surface and support it at position A, according to the figure on the right. Make sure the unit is stable and rests securily before removing the lifting equipment.
8.
xx0300000173
9. 10. 11. 12. 13. Remove the bottom plate from the base. Move the lifting straps to the base and unload its weight. Remove the attachment screws and washers, gearbox unit. Remove the base from the gearbox unit. Remove the sealing from the gearbox unit.
B: Approximately 200 mm
Shown in the figure Location of gearbox unit on page 209.
Shown in the figure Location of gearbox unit on page 209.
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4.7.2 Refitting of gearbox unit, axes 1-2-3
General
The gearboxes of axes 1-2-3 are handled as one complete unit. Except for the gearboxes, the spare part also includes motor units and lubricating oil for the axes 1, 2 and 3.
Location of gearbox unit
The gearbox unit, axes 1-2-3, is shown in the figure below. A more detailed view of the component and its position may be found in the Foldout section!
C
xx0300000174
A B C D
Gearbox unit axes 1-3, spare part Bottom plate Attachment screws and washers, gearbox unit Sealing
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Includes motors and lubricating oil. Includes motors and lubricating oil. Does not include motors or lubricating oil. Replace if damaged. 3HAC 17594-1 The contents are defined in section Standard toolkit in the Product manual, reference information! Lifting capacity: 500 kg. These procedures include references to the tools required. Gearbox unit, axes 1-3 3HAC 5948-1 (IRB 4400/45, /60, /L10, /L30) Gearbox unit, axes 1-3 (IRB 4400/S) Gearbox unit axes, 1-3 Sealing Standard toolkit 3HAC 5949-1 3HAC 3502-1 3HAC 5479-2
Lifting slings with hoisting block Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. Calibration Pendulum Instruction
Refitting, gearbox unit
The procedure below details how to refit the gearbox unit, including motors, 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. Caution! The gearbox unit weighs 360 kg! All lifting equipment used must be dimensioned accordingly! Caution! The base weighs 130 kg! All lifting equipment used must be dimensioned accordingly!
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Step
1.
Action
Info/Illustration
Place the new gearbox unit on a level Part no. is specified in Required equipsurface and support it at position A, ment on page 213. according to the figure on the right. Make sure the unit is stable and rests securily on the surface, including the weight of the base that is to be refitted.
xx0300000173
2. Refit the sealing to the gearbox unit. Replace it if damaged.
B: Approximately 200 mm
Shown in the figure Location of gearbox unit on page 212. Part no. is specified in Required equipment 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. Refit the base with the attachment screws and washers, gearbox unit. Shown in the figure Location of gearbox 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. Shown in the figure Location of gearbox unit on page 212.
4.
5. 6. 7.
Refit the bottom plate with its attachment screws.
Strap the gearbox unit as in the removal See section Removal, gearbox unit on instruction. page 210. 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. Refit the manipulator to the foundation.
8.
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Step
9. 10. 11. 12.
Action
Refit the complete arm system. Refit the parallel arm. Refit the tie rod.
Info/Illustration
Detailed in section Refitting of complete arm system on page 116. Detailed in section Refitting of parallel arm /Refitting of bearing on page 161. Detailed in section Refitting of tie rod on page 155.
Refit the cable harness and serial mea- Detailed in sections Refitting of cable harsuring board. ness, axes 1-3 on page 101, Refitting of cable harness, axes 4-6 on page 109and Replacement of serial measurement unit on page 173. Recalibrate the robot! Calibration with the Pendulum is detailed in the Calibration Pendulum Instruction, enclosed with the calibration toolkit. Other calibration is detailed in section Calibration on page 219.
13.
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4.7.3 Adjusting play on axis 4, intermediate gear
Illustration, adjusting play
In order to adjust the play on axis 4, the gear must be accessible. The figure below shows the parts in the upper arm housing that must be removed/unlocked.
B C A
xx0300000191
A B C
Cover Attachment screws, cover Screws, 3 pcs

Flange sealing Standard toolkit

1234 0011-116 3HAC 17594-1
Note
Loctite 574 The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Adjusting play, axis 4
The procedure below details how to adjust the play for the intermediate gear of axis 4.
216 Revision 3HAC 022032-001
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Step
1. 2. 3. 4. 5. 6.
Action
Remove the motors for axes 4, 5 and 6. Remove the cover . Unlock the three screws . Rotate axis 4 to find the highest position of the gear on the upper arm tubular. Tighten the three screws again.
Info/Illustration
Detailed in section Removal of motor, axes 4, 5 and 6 on page 198. Shown in the figure Illustration, adjusting play on page 216. Shown in the figure Illustration, adjusting play on page 216.
3 pcs, tightening torque: 69 Nm.
Apply flange sealing to the cover and refit Art. no. is specified in Required equipit with its attachment screws and washers ment on page 216. . 10 pcs: M8x40. Tightening torque: 24 Nm.
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5 Calibration
5.0.1 Introduction
5: Calibration
5.0.1 Introduction
Calibration methods
This chapter details how to calibrate the robot with the Wyler calibration equipment, using 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 values
Calibrate the measurement system carefully as detailed in section Calibration on page 230 if any of the resolver values have changed. This may occur when parts affecting the calibration position are replaced on the robot.
Contents of the revolution counter memory are lost
Calibrate the system roughly as detailed in section Updating the revolution counters on page 248 if the contents of the revolution counter memory are lost. This may occur when:
the battery is discharged a resolver error occurs the signal between a resolver and measurement board is interrupted a robot axis is moved with the control system disconnected
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5 Calibration
5.1.1 How to calibrate the robot system
5.1: Overview 5.1.1 How to calibrate the robot system
General
This section provides an overview of the procedures to perform when calibrating the robot system. Many of the steps in this overview are detailed in other sections to which references are given.
Method -Wyler Calibration
The calibration procedure with Wyler equipment may be performed with either one or two sensors. The procedure detailed here is performed with only one sensor and may be described as checking an pre-adjusted sensor, trying to obtain the same measurement value on every axis as when adjusted at the reference plane. All article numbers of relevant equipment are specified in their instructions respectively.
Overview, calibration Step

1. 2.
Action
Check that all required hardware is available for calibrating the robot.
Note
Required hardware is specified in the calibrating procedures for each axis.
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. Initialize the Levelmeter. Detailed in section Initialization of Levelmeter 2000 on page 228.
3. 4. 5. 6.
Start the calibration procedure on the Detailed in section Fine calibration proceTPU. dure on TPU on page 230. Calibrate each axis. Verify that the calibration was successfully carried out. Detailed in each axis calibration instruction. Detailed in section Post calibration procedure on page 250.
Additional information
In addition to the basic calibration procedure detailed above, a number of calibration related actions may be performed:
Action
Detailed in section:
How to update the robot revolution counter without perform- Updating the revolution ing a complete calibration. counters on page 248 How to manually check the current calibration position. Checking the calibration position on page 225
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5.1.2 Calibration, prerequisites
5.1.2 Calibration, prerequisites
Peripheral equipment
The robot must be free from any peripheral equipment during calibration. Fitted tools and similar will cause erroneous calibration positions.
Calibration order
The axes must be adjusted in increasing sequence, i.e. 1 - 2 - 3 - 4 - 5 - 6.
Location of sensors
The positions where the calibration sensor and reference sensor should be fitted during calibration, are specified in Positions and directions of sensor on page 226.
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5.2.1 Calibration scales and correct axis position
5.2: Reference information 5.2.1 Calibration scales and correct axis position
Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot models.
Safety information
Read the safety information below.
Warning! If work must be carried out within the robots work envelope, the following points must be observed: - The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel. - The robots speed is limited to max. 250 mm/s when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% full speedmay only be used by trained personnel who are aware of the risks that this entails. - Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell. - Test the motor brake on each axis, according to section Brake testing on page 28.
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5.2.1 Calibration scales and correct axis position
Calibration scales
The calibration marks for axes 2, 3, 4 and 5 are marked using punch mark tools. The illustration below shows the calibration scale positions:
E
xx0300000209
A B C D E 3HAC 022032-001
Punch, axis 2, 3HAB 1521-1 Punch, axis 3, 3HAB 1522-1 Punch, axis 4, 3HAB 1523-1 (there are two different versions of the marks, according to the figure) Punch, axis 5, 3HAB 1524-1 Axes 5 and 6, IRB 4400/L10 Revision 223
5 Calibration
5.2.2 Directions for all axes
5.2.2 Directions for all axes
Calibration movement directions
When calibrating, the axis must consistently be run towards the calibration position in the same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions are shown in the figure below. This is normally handled by the robot calibration software. Note! The figure shows an IRB 7600, but the positive direction is the same for all robots!
6+
4+
5+
3+ 2+
1+
xx0200000089
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5.2.3 Checking the calibration position
5.2.3 Checking the calibration position
General
Check the calibration position before beginning any programming of the robot system. This may be done in one of two ways:
Using the program CALxxxx in the system software (xxxx signifying the robot type; IRB xxxx) Using the Jogging window on the teach pendant
Using the program CALxxxx in the system software
Step
1.
Action
Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx in the system and follow the instructions displayed on the teach pendant. Switch to MOTORS OFF when the robot stops. Check that the calibration marks for that particular axis align correctly. If they do not, update the revolution counters. 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).
Button
2.
Calibration marks are shown in section Calibration scales and correct axis position on page 222. Detailed in section Updating the revolution counters on page 248.
3.
Using the Jogging window on the teach pendant
Step
1.
Action
Open the Jogging window.
Illustration
xx0100000195
2.
Choose running axis-by-axis.
xx0100000196
3. 4.
Manually run the robot axis to a position where the resolver offset value read, is equal to zero. Check that the calibration marks for that particu- Shown in section Calibration lar axis align correctly. If they do not, update the scales and correct axis position revolution counters ! on page 222. Detailed in section Updating the revolution counters on page 248.
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5.2.4 Positions and directions of sensor
General
This section details the mounting positions and directions for the
reference sensor calibration sensor
When calibrating an axis with only one sensor, the sensor must first be positioned at the base of the manipulator in order to create reference values. This is further detailed in section Resetting of Levelmeter 2000 and sensor on page 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 different locations. When using the sensor as a reference at the base, it is fitted to a sensor fixture together with a sensor plate, as shown in the figure below. The sensor has different directions, depending on which axis is calibrated. The directions are shown in the figure below.
Calibration and reference sensor position, IRB 4400
The sensor is positioned and aligned on the axes as shown in the figure below.
B B1
A D
C G F
H I
E
xx0300000204
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A B B1 C D E F G H I
Flange plate Axis 2 sensor Axis 2 sensor, view from above Axis 3 sensor Axis 4 sensor Axis 5 sensor Axis 6 sensor Upper arm, view from above Direction for sensor at reference plane, axis 2, 3 and 5 Direction for sensor at reference plane, axis 4 and 6
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5.2.5 Initialization of Levelmeter 2000
Overview
Whenever Levelmeter 2000 is used for calibrating the robot, the equipment must first be initialized as detailed in this section. Shown below is an outline of how to initialize the Levelmeter 2000. Detailed procedures are given further down.
1. Select the correct filter type, as detailed in Levelmeter 2000 on page 228. 2. Set the measuring unit, as detailed in Measuring units on page 229. 3. Install sensor, as detailed in Installation of sensor on page 229. 4. Calibrate the robot, as detailed in the instruction for each axis respectively, in the section Calibration on page 219!
Levelmeter 2000
The Levelmeter 2000 is shown for reference below:

+
Port/Sensor
0000000 00000
oo GON A oo mRAD mm/m DEG "1/12" "1/10" "/REL" mm/REL
A B
50
BA TT
LEVELMETER 2000
+
ZERO SELECT ON/MODE
ENTER
HOLD
WYLER
SEND/ESC
A
xx0200000083
OUT
A B C
Measuring unit Selection pointer Sensor connection
Select filter type Step

1. 2. 3.
Action
Info/Illustration
Press ON/MODE until the dot flashes under FIL- Shown in the figure Levelmeter TER . 2000 on page 228! Press ENTER. The standard filter type no. 5 flashes. Default setting is filter type 5.
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Step
4.
Action
If type 5 does not flash, press ZERO/SELECT to select filter type 5 and press ENTER .
Info/Illustration
Measuring units Step

1. 2. 3. 4.
Action
Press ON/MODE until the dot flashes under UNIT . Press ENTER. Press ZERO/SELECT until mm/m flashes. Two decimals (0.00) are shown on the display Press ENTER.
Info/Illustration
Shown in the figure Levelmeter 2000 on page 228!
Installation of sensor Step

1. 2. 3. 4. 5. 6. 7.
Action
Connect the sensor to the Sensor connection point. Press ON/MODE . Press ON/MODE until the dot flashes under SENSOR . Press ENTER. Press ZERO/SELECT until a flashing "A" is shown. Press ENTER. Wait until the "A" flashes again. Press ENTER.
Info/Illustration
Shown in the figure Levelmeter 2000 on page 228!
Result
The Levelmeter 2000 is now initialized and ready for service.
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5.3.1 Fine calibration procedure on TPU
5.3: Calibration 5.3.1 Fine calibration procedure on TPU
General
This section details how to use the Teach Pendant Unit (TPU) when performing a fine calibration of the robot. The method of fitting the calibration equipment to each axis is detailed in the calibration instruction for the axis.
Procedure Step
1.
Action
Press the button "Miscellaneous".
Note/Illustration
xx0100000194
2.
Select the Service window by pressing ENTER.

xx0100000200
3.
Select Calibration from the View menu. The Calibration window appears. If multiple units are connected to the robot, they will be listed in the window.
xx0100000201
The calibration status can be any of the following: Synchronized: all axes are calibrated and their positions are known. The unit is ready for use. Revolution Counter not updated: all axes are finecalibrated but one (or more) of the axes has a counter that is NOT updated. This axis, or these axes, must therefore be updated as detailed in section Updating the revolution counters on page 248. Not calibrated: one (or more) of the axes is NOT fine-calibrated. This axis, or these axes, must therefore be fine-calibrated as detailed in the calibration instructions for each axis.
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Step
4.
Action
Select the desired unit and choose Fine Calibrate from the Calib menu. A Warning window appears.
Note/Illustration
xx0100000203
5.
Move the manipulator Calibration positions for the manipulator are detailed in to its calibration posi- section Checking the calibration position on page 225. tion and press OK. The Fine Calibrate window appears.
xx0100000204
6.
Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes. Press OK when all axes that are to be updated are marked with an x. CANCEL returns to the Calibration window.
7.
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Step
8.
Action
Press OK again to confirm and start the update. CANCEL returns to the Fine Calibration window. An alert box is displayed during calibration. The Status window appears when the fine calibration is complete. The revolution counters are always updated at the same time as the calibration is performed.
Note/Illustration
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5.3.2 Resetting of Levelmeter 2000 and sensor
General
The equipment must first be reset before calibrating each axis. This section details how to reset the Levelmeter 2000 and make the one sensor ready for calibration.
Levelmeter 2000
The Levelmeter 2000 is shown for reference below:

+
Port/Sensor
0000000 00000
oo GON A oo mRAD mm/m DEG "1/12" "1/10" "/REL" mm/REL
A B
50
BA TT
LEVELMETER 2000
+
ZERO SELECT ON/MODE
ENTER
HOLD
WYLER
SEND/ESC
A
xx0200000083
OUT
A B C
Measuring unit Selection pointer Sensor connection
Sensor mounted on fixture
When using the sensor as a reference sensor it is fitted to the sensor fixture, together with a sensor plate, as shown below. See the section Positions and directions of sensor on page 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.
X Y B
xx0100000207
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A B C
Reference sensor, fitted to the sensor plate (actual direction differs) Sensor fixture, fitted on manipulator base Attachment screws, sensor plate

Levelmeter, one sensor Sensor plate Sensor fixture Isopropanol
Art. no.
6369 901-347 3HAC 0392-1 6808 0011-GM 1177 1012-108
Note
Includes one sensor.
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 calibration for each axis! Note! Always reset the sensor when using it in a new direction!
Resetting Step
1.
Action
Info/Illustration
If the sensor and the sensor plate are separate, Art. no. is specified in Required fit them together by first cleaning the attachequipment on page 234. ment area on the sensor plate with isopropanol and then fitting the sensor to it. Handle the sensor plate and the sensor as a complete unit when fitting it to and moving it between the reference point and the different axes. Make sure the Levelmeter is initialized according to section Initialization of Levelmeter 2000 on page 228. Remove the cover plate on the reference surface on the manipulator base. Clean the area where the sensor fixture is fitted with isopropanol . Fit the sensor fixture on the reference surface on the manipulator base. Art. no. is specified in Required equipment on page 234! Orientation is specified in section Positions and directions of sensor on page 226! Shown in the section Positions and directions of sensor on page 226.
2.
3.
4. 5.
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Step
6. 7.
Action
Clean the sensor plate attachment area on the fixture with isopropanol.
Info/Illustration
Fit the sensor unit (sensor plate and sensor) on Correct direction is shown in Posito the sensor fixture and connect the sensor to tions and directions of sensor on the Levelmeter 2000. page 226. Connection is shown in the figure Levelmeter 2000 on page 233. Press ON/MODE on the Levelmeter 2000 until Shown in the figure Levelmeter the dot flashes under REL ZERO . 2000 on page 233! Press ENTER. Wait until + or - flashes. Press HOLD . Wait until + or - flashes. Press ENTER.
8. 9. 10. 11. 12. 13.
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.
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5.3.3 Calibration, axis 1, IRB 4400
Calibration of axis 1
The special calibration equipment is fitted to the base of the manipulator as shown in the figure below.
A
xx0300000202
A B C
Guide pin in gearbox Calibration tool, axis 1 Measuring pin, axis 1

Isopropanol Calibration tool, axis 1 Measuring pin, axis 1 Guide bars

1177 1012-208 3HAB 1526-1 6808 0011-GR
Note
Used to clean the reference surface.
2 pcs Used to align the measurement pin.
Calibration, axis 1
The procedure below details how to perform the actual calibration of axis 1 using the calibration equipment specified in Required equipment. Caution! If the manipulator normally works in an inverted position, it must be removed from this position and placed on the floor before the work detailed in this instruction may be carried out !
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Step
1. 2.
Action
Move the robot to its calibration position corresponding to the calibration scales.
Info/Illustration
See section Calibration scales and correct axis position on page 222.
Remove the cover plate on the reference sur- Art. no. is specified in Required face on the base of the manipulator. equipment on page 236. Clean the surface with isopropanol and deburr it. Fit the calibration tool, axis 1 on the guide pin underneath the gearbox. Art. no. is specified in Required equipment on page 236. Shown in the figure Calibration of axis 1 on page 236. Art. no. is specified in Required equipment on page 236. Shown in the figure Calibration of axis 1 on page 236.
3.
4.
Fit the measuring pin to the calibration tool.
5.
Release the brakes and move the manipulator manually so that the measuring pin can be placed in the guide hole on the base. Put two guide bars on the tool and align the pin, as shown in the figure to the right.
6.
C A
B
xx0300000203
7. 8. 9. Update only axis 1, using the TPU. Remove the calibration tool for axis 1. Refit the cover plate to the reference surface on the base of the manipulator, if no other calibration is to be performed.
A: Calibration tool, axis 1 B: Measuring pin, axis 1 C: Guide bars
Detailed in section Fine calibration procedure on TPU on page 230.
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5.3.4 Calibration, axis 2
General
This section details how to perform the actual fine calibration of axis 2 using the Wyler calibration equipment.

Levelmeter 2000 calibration kit with one sensor Sensor plate Angle bracket Isopropanol Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Art. no.
6369 901-347 3HAC 0392-1 6808 0011-LP 1177 1012-108
Note
Includes one sensor. One sensor plate is required for each sensor! For calibration sensor on manipulator lower arm. For cleaning the attachment points. These procedures include references to the tools required.
Tip! Lock the axes previous to the one calibrated to minimize the risk of accidentally moving other axes! In case of accidental movement of previous axes, the calibration procedure must be restarted from the moved axis and continued in increasing sequence!
Procedure Step
1.
Action
Illustration
Reset the levelmeter and the sensor for cal- Detailed in section Resetting of Levibration of axis 2. elmeter 2000 and sensor on page 233. Clean the calibration surface with isopropanol. Fit the angle bracket on the lower arm. Adjust the angle of the bracket to make it level. Art. no. is specified in Required equipment on page 238! Art. no. is specified in Required equipment on page 238!
2. 3.
4.
Fit the calibration sensor together with the Shown in section Positions and direcsensor plate on the angle bracket on axis 2. tions of sensor on page 226! Carefully tighten the securing screws with approximately same tightening torque that used at the reference plane!
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Step
5.
Action
Illustration
Manually run axis 2 in with the joystick to Correct measurement on the levelthe correct position as indicated by the lev- meter: elmeter. 0 0.40 mm/m
Tip!
Reduce the jogging velocity in order to easily position the axis as close to zero as possible! 6. 7. 8. Update only axis 2. Remove the sensor. Refit the cover plate on the calibration surface on the manipulator lower arm. Refit also the cover plate on the reference surface at the base if no further calibration is performed. Check the calibration according to section Post calibration procedure on page 250 or continue with calibration of next axis. Detailed in section Fine calibration procedure on TPU on page 230.
9.
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General

Sync adapter Guide pin Levelmeter 2000 calibration kit with one sensor Sensor plate Turning disk fixture Isopropanol Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
Art. no.
3HAB 1525-1 2111 2021-399 6369 901-347 3HAC 0392-1 6808 0011-GU 1177 1012-108
Info
Adapter to be fitted on the turning disk. Includes guide pin 2111 2021-399. To be used with Sync adapter. Includes one sensor. One sensor plate is required for each sensor. For fitting the calibration sensor plate to the sync adapter. For cleaning the attachment points. These procedures include references to the tools required.
Procedure Step
1. 2.
Action
Illustration/Info
Clean the manipulator turning disk with isopro- Art. no. is specified in Required panol. equipment on page 240! Fit the sync adapter to the turning disk. Fit the turning disk fixture (incl. guide pin) on the turning disk. Turn the tool clockwise against the pin at the same time as the screws are tightened. Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx (xxxx=robot model, e.g. 7600) in the system and select Calib: CAL3. The robot moves to the position for calibration of axis 3. Reset the levelmeter with correct orientation of Detailed in section Resetting of the sensor for calibration of axis 3. Levelmeter 2000 and sensor on page 233. Art. no. is specified in Required equipment on page 240!
3. 4.
5.
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Step
6.
Action
Fit the calibration sensor unit (sensor and plate) on the turning disk fixture. Carefully tighten the securing screws with approximately same tightening torque that used at the reference plane.
Illustration/Info
Shown in the section Positions and directions of sensor on page 226!
7.
Manually run axis 3 in with the joystick to the Correct measurement on the levcorrect position as indicated by the levelmeter. elmeter: 0 0.40 mm/m
Tip!
Reduce the jogging velocity in order to easily position the axis as close to zero as possible! 8. Update only axis 3. Detailed in section Fine calibration procedure on TPU on page 230.
9. 10.
Remove the sensor. Check the calibration according to section Post calibration procedure on page 250 or continue with calibration of next axis. Refit the cover plate on the reference surface on the base if no further calibration is performed.
11.
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General
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. Includes one sensor. One sensor plate is required for each sensor. For fitting the calibration sensor plate to the sync adapter. For cleaning the attachment points. These procedures include references to the tools required.
Levelmeter 2000 calibration 6369 901-347 kit with one sensor Sensor plate Turning disk fixture Isopropanol Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. 3HAC 0392-1 6808 0011-GU 1177 1012-108
Procedure Step
1. 2.
Action
Clean the manipulator turning disk with isopropanol .
Illustration
Art. no. is specified in Required equipment on page 242!
Fit the sync adapter to the turning disk. Art. no. is specified in Required Fit the turning disk fixture (incl. pin) on the turning equipment on page 242! disk. Turn the tool clockwise against the pin at the same time as the screws are tightened. Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx (xxxx=robot model, e.g. 7600) in the system and select Calib: CAL4A. The robot moves to the position for calibration of axis 4. Reset the levelmeter with correct orientation of the sensor for calibration of axis 4. Detailed in section Resetting of Levelmeter 2000 and sensor on page 233. 3HAC 022032-001
3. 4.
5.
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Step
6.
Action
Fit the calibration sensor unit (sensor and plate) on the turning disk fixture. Carefully tighten the securing screws with approximately same tightening torque that used at the reference plane.
Illustration
7.
Manually run axis 4 in with the joystick to the cor- Correct measurement on the rect position as indicated by the levelmeter. levelmeter: 0 0.80 mm/m
Tip!
Reduce the jogging velocity in order to easily position the axis as close to zero as possible! 8. Update only axis 4. Detailed in section Fine calibration procedure on TPU on page 230.
9. 10. 11.
Remove the sensor. Select Calib: CAL4B. The axis 4 moves 90, to a correct position. Update only axis 4. Detailed in section Fine calibration procedure on TPU on page 230.
12.
Check the calibration according to section Post calibration procedure on page 250 or continue with calibration of next axis. Refit the cover plate on the reference surface at the base if no further calibration is performed.
13.
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General

Sync adapter Guide pin Levelmeter 2000 calibration kit with one sensor Sensor plate Turning disk fixture Isopropanol Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
Art. no.
3HAB 1525-1 2111 2021-399 6369 901-347 3HAC 0392-1 6808 0011-GU 1177 1012-108
Info
Adapter to be fitted on the turning disk. Includes guide pin 2111 2021-399. To be used with Sync adapter.
One sensor plate is required for each sensor. For fitting the calibration sensor plate to the sync adapter. For cleaning the attachment points. These procedures include references to the tools required.
Procedure Step
1. 2.
Action
Illustration
Clean the manipulator turning disk with isopro- Art. no. is specified in Required panol . equipment on page 244! Fit the sync adapter to the turning disk. Fit the turning disk fixture (incl. pin) on the turning disk. Turn the tool clockwise against the pin at the same time as the screws are tightened. Run the program \SYSTEM\UTILITY\SERVICE\CALIBRAT\CALxxxx (xxxx=robot model, e.g. 7600) in the system and select Calib: CAL5. The robot will now move to the position for calibration of axis 5. Reset the levelmeter with correct orientation of Detailed in section Resetting of the sensor for calibration of axis 5. Levelmeter 2000 and sensor on page 233. Art. no. is specified in Required equipment on page 244!
3. 4.
5.
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Step
6.
Action
Fit the calibration sensor on the turning disk fixture. Carefully tighten the securing screws with approximately same tightening torque that used at the reference plane.
Illustration
7.
Manually run axis 5 in with the joystick to the Correct measurement on the levelcorrect position as indicated by the levelmeter. meter: 0 0.80 mm/m
Tip!
Reduce the jogging velocity in order to easily position the axis as close to zero as possible! 8. 9. 10. Update only axis 5. Remove the sensor. Check the calibration according to section Post calibration procedure on page 250 or continue with calibration of next axis. Refit the cover plate on the reference surface at the base if no further calibration is performed. Detailed in section Fine calibration procedure on TPU on page 230.
11.
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General

Sync adapter Guide pin
Art. no.
3HAB 1525-1 2111 2021-399
Info
Adapter to be fitted on the turning disk. Includes guide pin 2111 2021-399. To be used with Sync adapter.
Levelmeter 2000 calibration kit 6369 901-347 with one sensor Sensor plate Turning disk fixture Isopropanol Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. 3HAC 0392-1 6808 0011-GU 1177 1012-108 One sensor plate is required for each sensor. For fitting the calibration sensor plate to the sync adapter. For cleaning the attachment points. These procedures include references to the tools required.
Procedure Step
1. 2. 3.
Action
Calibrate axis 5. Reset the levelmeter with correct orientation of the sensor for calibration of axis 6.
Illustration
Detailed in section Calibration, axis 5 on page 244. Detailed in section Resetting of Levelmeter 2000 and sensor on page 233.
Fit the calibration sensor unit (sensor and Shown in section Positions and direcplate) on the turning disk fixture. tions of sensor on page 226! Carefully tighten the securing screws with approximately same tightening torque that used at the reference plane.
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Step
4.
Action
Illustration
Manually run axis 6 in with the joystick to Correct measurement on the levelmethe correct position as indicated by the lev- ter: elmeter. 0 0.80 mm/m
Tip!
Reduce the jogging velocity in order to easily position the axis as close to zero as possible! 5. 6. 7. 8. Update only axis 6. Remove the sensor. Check the calibration according to section Post calibration procedure on page 250. Refit the cover plate on the reference surface at the base. Detailed in section Fine calibration procedure on TPU on page 230.
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5.3.9 Updating the revolution counters
Manually running the manipulator to the calibration position
This section details the first step when updating the revolution counter; manually running the manipulator to the calibration position.
Step
1. 2.
Action
Select axis-by-axis motion mode.
Illustration
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! Note that axis 6 does not have any mechanical stop and can thus be calibrated at the wrong faceplate revolution. Do not operate axis 6 manually before the robot has been calibrated. When all axes are positioned as above, store the revolution counter settings using the Teach Pendant Unit as detailed below:
3.
4.
Storing the revolution counter setting
This section details the second step when updating the revolution counter; storing the revolution counter setting.
Caution! If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury! Check the calibration very carefully after each update!
Step
1.
Action
Press the button "Miscellaneous".
Illustration
xx0100000194
2.
Select the Service window by pressing ENTER.

xx0100000200
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Step
3.
Action
Select Calibration from the View menu. The Calibration window appears. If there is more than one unit connected to the robot, they will be listed in the window.
Illustration
xx0100000201
4.
Select the desired unit and choose Rev Counter Update from the Calib menu. The Revolution Counter Update window appears.
xx0100000202
5.
Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes. Press OK when all axes that are to be updated are marked with an x. CANCEL returns to the Calibration window. Press OK again to confirm and start the update. CANCEL returns to the Revolution Counter Update window. At this point, it is recom- Not required. mended that the revolution counter values are saved to a diskette. Recheck the calibration position. Detailed in section Checking the calibration position on page 225
6.
7.
8.
9.
3HAC 022032-001
Revision -
249
5 Calibration
5.4.1 Post calibration procedure
5.4: After calibration 5.4.1 Post calibration procedure
General
Perform the following procedure after calibrating any manipulator axes. The procedure is intended to verify that all calibration positions are correct.
Procedure Step
1.
Action
Run the calibration home position program twice. Do not change the position of the manipulator axes after running the program!
Illustration
Detailed in section Checking the calibration position on page 225.
2.
Check the calibration positions. Detailed in section Checking the Check the calibration positions of axes 6, 2 and calibration position on page 225. 5. If axes 5 and 6 are within the tolerances given below, then axes 3 and 4 do not need to be checked. The acceptable accurancy is: axis 2, 3: 0.20 mm/m axis 4, 5, 6: 0.40 mm/m If the axes are outside the tolerance, start the calibration procedure from the beginning, in increasing sequence of the axes.
3. 4.
Repeat the check as above. Adjust the calibration marks when the calibration is done. The system parameters will be saved to the storage memory at power off. Change the values on a new label and stick it on top of the label located underneath the flange plate on the base. Remove any calibration equipment from the manipulator. Shown in section Calibration scales and correct axis position on page 222.
5. 6.
7.
250
Revision -
3HAC 022032-001
6 Calibration, M2004
6.0.1 Introduction
6: Calibration, M2004
6.0.1 Introduction
Calibration
This chapter will describe how to calibrate the robot with the Wyler calibration equipment, using Levelmeter 2000, when the robot is part of an M2004 robot system (IRC5 controller). This chapter will be completed in the upcoming revision of the manual.
3HAC 022032-001
Revision -
251
6 Calibration, M2004
6.0.1 Introduction
252
Revision -
3HAC 022032-001
Index
C Calibration position, 248 R Revolution counters, 248 U Updating revolution counters, 248
3HAC 022032-001
253
Index
254
3HAC 022032-001

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

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Product manual, procedures

Product manual, procedures

1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

3.1.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 3.1.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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

5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219

5.4.1 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 6: Calibration, M2004 251

6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251

About this manual

This manual contains instructions for

This manual should be used during

Who should read this manual?

This manual is intended for:

The reader should...

The manual is organized in the following chapters:

References Reference Document Id

0.0.2 Reading the product manual

0.0.2 Reading the product manual

Reading the instructions

References to required equipment

0.0.2 Reading the product manual

0.0.3 Product documentation, M2000

0.0.3 Product documentation, M2000

Product manual, reference information

Hardware option manual

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

0.0.3 Product documentation, M2000

0.0.4 Product documentation, M2004

0.0.4 Product documentation, M2004

Product manual, reference information

0.0.4 Product documentation, M2004

1.1: General information 1.1.1 Safety, service - General

Validity and responsibility

Connection of external safety devices

1.1.2 Limitation of Liability

1.1.3 Related information

The list below specifies documents which contain useful information:

Documents Type of information

Restricting the working space Product manual for the manipulator

1.2: Safety risks 1.2.1 Safety risks related to gripper

1.2.2 Safety risks related to tools/workpieces

1.2.3 Safety risks related to pneumatic/hydraulic systems

Special safety regulations apply to pneumatic and hydraulic systems.

1.2.4 Safety risks during operational disturbances

1.2.5 Safety risks during installation and service

General risks during installation and service

Nation/region specific regulations

Non-voltage related risks

To be observed by the supplier of the complete system

1.2.6 Risks associated with live electric parts

Voltage related risks, general

Voltage related risks, controller

A danger of high voltage is associated with the following parts:

Voltage related risks, manipulator

A danger of high voltage is associated with the manipulator in:

Voltage related risks, tools, material handling devices, etc

1.3: Safety actions 1.3.1 Safety fence dimensions

1.3.2 Fire extinguishing

1.3.3 Emergency release of the manipulators arm

1.3.4 Brake testing

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