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ABB IRB 2400/10 Product Manual

Manual is about: Articulated robot

Summary of IRB 2400/10

  • Page 1

    Product manual articulated robot irb 2400/l irb 2400/10 irb 2400/16 m2000, m2000a, m2004.

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    © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Product manual irb 2400/l irb 2400/10 irb 2400/16 m2000 m2000a m2004 document id: 3hac022031-001 revision: c.

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    © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 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 ...

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    Table of contents 3 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 how to read the product manual...

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    Table of contents 4 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3 maintenance 65 3.1 introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 3.2 maintenace s...

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    Table of contents 5 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6.4 screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 6.5 weight specifications . . . . ...

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    Table of contents 6 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed..

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    Overview 7 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Overview about this manual this manual contains instructions for • mechanical and electrical installation of the robot • maintenance of the robot • mechanical and electrical repair of the robot. Usage thi...

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    Overview 3hac022031-001 revision: c 8 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. References procedures in this product manual contain references to the following manuals: additional document references revisions document name document id note product specification - irb 2400 3hac9112-...

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    Overview 9 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. C cleanroom added. Changes made in: • prerequisites in section overview • oil change in section maintenance revision description continued.

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    How to read the product manual 3hac022031-001 revision: c 10 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. How to read the product manual reading the procedures the procedures contain references to figures, tools, material etc. The references are read as described below. References to fi...

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    Product documentation, m2000/m2000a 11 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Product documentation, m2000/m2000a general the complete product documentation kit for the m2000 robot system, including controller, robot and any hardware option, consists of ...

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    Product documentation, m2004 3hac022031-001 revision: c 12 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Product documentation, m2004 general the robot documentation is divided into a number of categories. This listing is based on the type of information contained within the documents, r...

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    Product documentation, m2004 13 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Operating manuals this group of manuals is aimed at those having first hand operational contact with the robot, that is production cell operators, programmers and trouble shooters. Th...

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    Product documentation, m2004 3hac022031-001 revision: c 14 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed..

  • Page 17: 1 Safety

    1 safety 1.1. Introduction 15 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1 safety 1.1. Introduction overview the safety information in this manual is divided in two categories: • general safety aspects, important to attend to before performing any service wo...

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    1 safety 1.2.1. Safety in the robot system 3hac022031-001 revision: c 16 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2 general safety information 1.2.1. Safety in the robot system validity and responsibility the information does not cover how to design, install and operate a complete...

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    1 safety 1.2.2.1. Safety risks during installation and service work on robot 17 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.2. Safety risks 1.2.2.1. Safety risks during installation and service work on robot overview this section includes information of g...

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    1 safety 1.2.2.1. Safety risks during installation and service work on robot 3hac022031-001 revision: c 18 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Complete robot cabling gearboxes and motors safety risk description hot components! Caution! Motors and gears are hot after running the...

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    1 safety 1.2.2.2. Safety risks related to tools/workpieces 19 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.2.2. Safety risks related to tools/workpieces safe handling it must be possible to safely turn off tools, such as milling cutters, etc. Make sure tha...

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    1 safety 1.2.2.3. Safety risks related to pneumatic/hydraulic systems 3hac022031-001 revision: c 20 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.2.3. Safety risks related to pneumatic/hydraulic systems general special safety regulations apply to pneumatic and hydraulic systems. Resi...

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    1 safety 1.2.2.4. Safety risks during operational disturbances 21 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.2.4. Safety risks during operational disturbances general • the industrial robot is a flexible tool which can be used in many different industria...

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    1 safety 1.2.2.5. Risks associated with live electric parts 3hac022031-001 revision: c 22 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.2.5. Risks associated with live electric parts voltage related risks, general • although troubleshooting may, on occasion, need to be carried out wh...

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    1 safety 1.2.2.5. Risks associated with live electric parts 23 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Voltage related risks, irc5 controller a danger of high voltage is associated with, for example, the following parts: • be aware of stored electrical en...

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    1 safety 1.2.3.1. Safety fence dimensions 3hac022031-001 revision: c 24 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.3. Safety actions 1.2.3.1. Safety fence dimensions general install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning dimens...

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    1 safety 1.2.3.2. Fire extinguishing 25 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.3.2. Fire extinguishing note! Use a carbon dioxide (co 2 ) extinguisher in the event of a fire in the robot system (robot or controller)!.

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    1 safety 1.2.3.3. Emergency release of the robot’s arm 3hac022031-001 revision: c 26 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.3.3. Emergency release of the robot’s arm description in an emergency situation, any of the robot's axes may be released manually by pushing the brake re...

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    1 safety 1.2.3.4. Brake testing 27 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.3.4. Brake testing when to test during operation the holding brake of each axis motor wear normally. A test may be performed to determine whether the brake can still perform it...

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    1 safety 1.2.3.5. Risk of disabling function "reduced speed 250 mm/s" 3hac022031-001 revision: c 28 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.3.5. Risk of disabling function "reduced speed 250 mm/s" note! Do not change "transm gear ratio" or other kinematic system parameters from...

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    1 safety 1.2.3.6. Safe use of the flexpendant 29 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.3.6. Safe use of the flexpendant note! The enabling device is a push button located on the side of the flexpendant which, when pressed halfway in, takes the syste...

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    1 safety 1.2.3.7. Work inside the robot's working range 3hac022031-001 revision: c 30 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.3.7. Work inside the robot's working range warning! If work must be carried out within the robot’s work envelope, the following points must be observed:...

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    1 safety 1.2.3.8. Translate the information on safety and information labels 31 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.2.3.8. Translate the information on safety and information labels labels on the product both the robot and the controller are marked ...

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    1 safety 1.3.1. Safety signals, general 3hac022031-001 revision: c 32 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.3 safety related instructions 1.3.1. Safety signals, general general this section specifies all dangers that may arise from performing the work detailed in the manual. Ea...

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    1 safety 1.3.1. Safety signals, general 33 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Electrostatic discharge (esd) electrostatic discharge (esd) the electrostatic discharge (esd) symbol indicates electrostatic hazards which could result in severe damage to ...

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    1 safety 1.3.2. Danger - moving robots are potentially lethal! 3hac022031-001 revision: c 34 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.3.2. Danger - moving robots are potentially lethal! Description any moving robot is a potentially lethal machine. When running the robot, it may pe...

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    1 safety 1.3.3. Danger - first test run may cause injury or damage! 35 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.3.3. Danger - first test run may cause injury or damage! Description since performing a service activity often requires disassembly of the rob...

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    1 safety 1.3.4. Warning - the unit is sensitive to esd! 3hac022031-001 revision: c 36 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.3.4. Warning - the unit is sensitive to esd! Description esd (electrostatic discharge) is the transfer of electrical static charge between two bodies at d...

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    1 safety 1.3.5. Warning - safety risks during work with gearbox oil 37 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1.3.5. Warning - safety risks during work with gearbox oil description when handling the gearbox oil, there are several dangers to both personal...

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    1 safety 1.3.5. Warning - safety risks during work with gearbox oil 3hac022031-001 revision: c 38 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed..

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    2 installation and commissioning 2.1. Introduction 39 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2 installation and commissioning 2.1. Introduction general this chapter contains information for installing the robot to the working site. More detailed technica...

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    2 installation and commissioning 2.2.1. Pre-installation procedure 3hac022031-001 revision: c 40 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.2 unpacking 2.2.1. Pre-installation procedure general these instructions are to be used when unpacking and installing the robot for the first t...

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    2 installation and commissioning 2.2.1. Pre-installation procedure 41 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Irb 2400 - l requirements, foundation the table below shows the requirements for the foundation where the weight of the installed robot is includ...

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    2 installation and commissioning 2.2.2. Working range 3hac022031-001 revision: c 42 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.2.2. Working range working range this section specifies the working areas of the robot models. Irb 2400/l the working area is the same for both floor and in...

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    2 installation and commissioning 2.2.2. Working range 43 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Irb 2400/10, /16 the working area is the same for both floor and inverted (suspended). Positions are located at wrist center. Xx0200000160 positions in the wo...

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    2 installation and commissioning 2.3.1. Lifting robot with lifting slings 3hac022031-001 revision: c 44 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.3 on-site installation 2.3.1. Lifting robot with lifting slings general this section details how to lift the robot using lifting slings....

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    2 installation and commissioning 2.3.2. Manually releasing the brakes 45 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.3.2. Manually releasing the brakes general the holding brakes of each axis’ motor are of an electromechanical type and are released when vol...

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    2 installation and commissioning 2.3.2. Manually releasing the brakes 3hac022031-001 revision: c 46 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Supplying power to connector r1.Mp if the robot is not connected to the controller, power must be supplied to connector r1.Mp in the robot bas...

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    2 installation and commissioning 2.3.3. Orienting and securing the robot 47 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.3.3. Orienting and securing the robot general this section details how to orient and secure the robot to the foundation in order to safel...

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    2 installation and commissioning 2.3.3. Orienting and securing the robot 3hac022031-001 revision: c 48 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Cross section, guide sleeve hole the figure below shows the cross section of the guide sleeve holes (from previous figure): xx0200000182 gu...

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    2 installation and commissioning 2.3.4. Suspended mounting 49 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.3.4. Suspended mounting general the robot can be mounted in a suspended position. This section details how to turn the robot. Turning the robot 1. Use ...

  • Page 52

    2 installation and commissioning 2.3.5. Loads 3hac022031-001 revision: c 50 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.3.5. Loads general any loads mounted on the robot must be defined correctly and carefully (with regard to the position of center of gravity and mass moments of iner...

  • Page 53

    2 installation and commissioning 2.4.1. Introduction 51 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.4 restricting the working range 2.4.1. Introduction general when installing the robot, make sure that it can move freely within its entire working space. If ...

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    2 installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 3hac022031-001 revision: c 52 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.4.2. Mechanically restricting the working range of axis 1 restrictions in the working range the working range of axis...

  • Page 55

    2 installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 53 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Required equipment fitting, mechanical stop axis 1 the procedure below details how to fit a mechanical stop to the robo...

  • Page 56

    2 installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 3hac022031-001 revision: c 54 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Location of where to drill holes for extra stops the figure below shows the drill pattern used when drilling for mechan...

  • Page 57

    2 installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 55 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Hidden stiffening ribs and forbidden drilling sector xx0600002647 * the minimum and maximum measurement between the mec...

  • Page 58

    2 installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 3hac022031-001 revision: c 56 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Drill template xx0200000207 continued.

  • Page 59

    2 installation and commissioning 2.4.3. Mechanically restricting the working range of axis 2 57 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.4.3. Mechanically restricting the working range of axis 2 general the range of rotation for axis 2 can be limited mec...

  • Page 60

    2 installation and commissioning 2.4.3. Mechanically restricting the working range of axis 2 3hac022031-001 revision: c 58 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Standard toolkit - the content is defined in section standard toolkit on page 178 . Equipment art. No. Note continued.

  • Page 61

    2 installation and commissioning 2.4.4. Installation of limit switch, axis 3 59 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.4.4. Installation of limit switch, axis 3 general the working range of axis 3 can be limited by fitting an electrical switch on the g...

  • Page 62

    2 installation and commissioning 2.5.1. Connectors on robot 3hac022031-001 revision: c 60 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.5 electrical connections 2.5.1. Connectors on robot connectors on the robot the figure below shows all connections of the robot cabling, including the...

  • Page 63

    2 installation and commissioning 2.5.2. Robot cabling and connection points 61 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.5.2. Robot cabling and connection points general connect the robot and controller to each other after securing them to the foundation....

  • Page 64

    2 installation and commissioning 2.5.2. Robot cabling and connection points 3hac022031-001 revision: c 62 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Robot cable, signals position switch cables, robot base to controller (option) these cables are not included in the standard delivery, b...

  • Page 65

    2 installation and commissioning 2.6.1. Additional installation procedure. 63 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2.6 making robot ready for operation (cleanroom) 2.6.1. Additional installation procedure. General cleanroom robots are specially designe...

  • Page 66

    2 installation and commissioning 2.6.1. Additional installation procedure. 3hac022031-001 revision: c 64 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed..

  • Page 67: 3  Maintenance

    3 maintenance 3.1. Introduction 65 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3 maintenance 3.1. Introduction structure of this chapter this chapter details all maintenance activities recommended for the robot and any external units of the robot. It is based...

  • Page 68

    3 maintenance 3.2.1. Specification of maintenance intervals 3hac022031-001 revision: c 66 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3.2 maintenace schedule 3.2.1. Specification of maintenance intervals description the intervals may be specified in different ways depending on the type...

  • Page 69

    3 maintenance 3.2.2. Maintenance schedule 67 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3.2.2. Maintenance schedule general the robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table ...

  • Page 70

    3 maintenance 3.3.1. Oil in gearboxes 3hac022031-001 revision: c 68 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3.3 changing activites 3.3.1. Oil in gearboxes type and amount of oil in the gearboxes gearbox type of oil art. No. Amount axis 1 mobilgear 600 xp320 11712016-604 6,400 ml ax...

  • Page 71

    3 maintenance 3.3.2. Oil change, gearbox axes 5-6 (wrist unit) 69 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3.3.2. Oil change, gearbox axes 5-6 (wrist unit) location of oil plugs, gearbox axes 5-6 the oil plugs are located at the wrist unit as shown in the ...

  • Page 72

    3 maintenance 3.3.2. Oil change, gearbox axes 5-6 (wrist unit) 3hac022031-001 revision: c 70 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refilling, gearbox axes 5-6 the procedure below details how to refill oil to the wrist unit. 2. Danger! Turn off all electric power, hydraulic and pn...

  • Page 73

    3 maintenance 3.3.2. Oil change, gearbox axes 5-6 (wrist unit) 71 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3. Warning! Handling gearbox oil involves several safety risks. Before proceeding, please observe the safety information in section warning - safety ...

  • Page 74

    3 maintenance 3.3.3. Replacement of smb battery unit 3hac022031-001 revision: c 72 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3.3.3. Replacement of smb battery unit location of smb battery unit the smb battery unit is located inside the robot base, as shown in the figure below. Xx0300...

  • Page 75

    3 maintenance 3.3.3. Replacement of smb battery unit 73 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Replacement, smb battery the procedure below details how to replace the smb battery. Action note 1. Danger! Turn off all electric power, hydraulic and pneumati...

  • Page 76

    3 maintenance 3.3.3. Replacement of smb battery unit 3hac022031-001 revision: c 74 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed..

  • Page 77: 4  Repair

    4 repair 4.1. Introduction 75 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4 repair 4.1. Introduction structure of this chapter this chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate ...

  • Page 78

    4 repair 4.2.1. Performing a leak-down test 3hac022031-001 revision: c 76 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.2 general procedures 4.2.1. Performing a leak-down test general after refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be te...

  • Page 79

    4 repair 4.2.2. Mounting instructions for bearings 77 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.2.2. Mounting instructions for bearings general this section details how to mount and grease different types of bearings on the robot. Equipment assembly of al...

  • Page 80

    4 repair 4.2.2. Mounting instructions for bearings 3hac022031-001 revision: c 78 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Greasing of bearings the bearings must be greased after assembly, according to instructions below: • the bearings must not be completely filled with grease. Howe...

  • Page 81

    4 repair 4.2.3. Mounting instructions for seals 79 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.2.3. Mounting instructions for seals general this sections details how to mount different types of seals to the robot. Equipment rotating seals the procedure belo...

  • Page 82

    4 repair 4.2.3. Mounting instructions for seals 3hac022031-001 revision: c 80 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Flange seals and static seals the procedure below details how to fit flange seals and static seals. O-rings the procedure below details how to fit o-rings. Action 1...

  • Page 83

    4 repair 4.3.1. Replacement of cable unit, axes 1-3 81 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.3 complete robot 4.3.1. Replacement of cable unit, axes 1-3 location of cabling the cable unit of axes 1-3 is run from the base of the robot to the motors, ax...

  • Page 84

    4 repair 4.3.1. Replacement of cable unit, axes 1-3 3hac022031-001 revision: c 82 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Removal, cable unit, axes 1-3 the procedure below details how to remove the cabling of axes 1-3. Sealing 3hac4113-1 sealing in the base for the cables. Always u...

  • Page 85

    4 repair 4.3.1. Replacement of cable unit, axes 1-3 83 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6. Loosen the nuts (d) and remove the smb unit carefully from the bracket. The cable (a) between the battery (b) and the smb unit (c) may stay connected, in ord...

  • Page 86

    4 repair 4.3.1. Replacement of cable unit, axes 1-3 3hac022031-001 revision: c 84 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, cable unit, axes 1-3 the procedure below details how to refit the cabling of axes 1-3 to the robot. 11. Remove the cover of the motors 1-3. 12. Disco...

  • Page 87

    4 repair 4.3.1. Replacement of cable unit, axes 1-3 85 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6. Refit the upper bracket securing the cables to the arm house, using the two attachment screws. 7. Fit the cable guide to the harness and secure the holder to...

  • Page 88

    4 repair 4.3.1. Replacement of cable unit, axes 1-3 3hac022031-001 revision: c 86 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 10. Refit the smb unit to the bracket with the nuts (d). Be careful not to let the weight of the smb-unit strain the cable! (a). Xx0200000398 note! The cable (a...

  • Page 89

    4 repair 4.3.2. Replacement of cable harness, axes 4-6 87 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.3.2. Replacement of cable harness, axes 4-6 location of cable harness the cable harness runs throughout the robot as shown in the figure below. Xx020000039...

  • Page 90

    4 repair 4.3.2. Replacement of cable harness, axes 4-6 3hac022031-001 revision: c 88 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Required equipment removal, cable harness, axes 4-6 the procedure below details how to remove the cable harness, axes 4-6. Equipment, etc. Spare part no. Art...

  • Page 91

    4 repair 4.3.2. Replacement of cable harness, axes 4-6 89 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4. Disconnect connectors r1.Mp4-6 and r2.Bu4-6. 5. Disconnect all the earth cables on the r1.M4-6 cable from the back of the cover. Xx0200000403 6. Loosen th...

  • Page 92

    4 repair 4.3.2. Replacement of cable harness, axes 4-6 3hac022031-001 revision: c 90 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 9. Remove the adapter plate from the harness by removing its two attachment screws (a). Xx0200000404 note! Different robot versions are fitted with different...

  • Page 93

    4 repair 4.3.2. Replacement of cable harness, axes 4-6 91 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, cable harness, axes 4-6 the procedure below details how to refit the cable harness, axes 4-6. Action note/illustration 1. Danger! Turn off all ele...

  • Page 94

    4 repair 4.3.2. Replacement of cable harness, axes 4-6 3hac022031-001 revision: c 92 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 5. Reconnect all connectors at motor 4, 5 and 6. R3.Mp 4-6 (a) and r3.Fb 1-3 (b) a - r3.Mp5 b - r3.Mp6 c - r3.Mp4 d - r3.Fb5 e - r3.Fb6 f - r3.Fb4 xx02000004...

  • Page 95

    4 repair 4.3.2. Replacement of cable harness, axes 4-6 93 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 7. Fit the upper bracket securing the cables to the arm house, using the two attachment screws. 8. Fit the adapter plate to the harness by using its two atta...

  • Page 96

    4 repair 4.3.2. Replacement of cable harness, axes 4-6 3hac022031-001 revision: c 94 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 11. Fit the smb-unit to the bracket with the nuts (d), be careful not to let the weight of the smb-unit strain the battery cable! (a). Xx0200000398 note! The...

  • Page 97

    4 repair 4.4.1. Replacement of wrist irb 2400/10/16 95 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.4 upper arm 4.4.1. Replacement of wrist irb 2400/10/16 location of wrist the wrist is defined as the axis 5 and 6 of the robot. This is shown in pos (a) in th...

  • Page 98

    4 repair 4.4.1. Replacement of wrist irb 2400/10/16 3hac022031-001 revision: c 96 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Wrist unit xx0300000104 required equipment a attachment screws and washers b oil plug c wrist equipment, etc. Spare part no. Art. No. Note wrist 3hab9398-1 o-ri...

  • Page 99

    4 repair 4.4.1. Replacement of wrist irb 2400/10/16 97 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Removal, wrist unit the procedure below details how to remove the wrist from the robot upper arm. The wrist, which includes axes 5 and 6, is a complete unit com...

  • Page 100

    4 repair 4.4.1. Replacement of wrist irb 2400/10/16 3hac022031-001 revision: c 98 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6. In order to release the brakes, connect the 24 vdc power supply to the motor. Note! Release the brakes of the two motors, but one at a time! Connect to motor...

  • Page 101

    4 repair 4.4.2. Replacement of wrist irb 2400l 99 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.4.2. Replacement of wrist irb 2400l location of wrist the wrist is defined as the axis 5 and 6 of the robot and shown in pos (a) in the figure below. X0300000409 r...

  • Page 102

    4 repair 4.4.2. Replacement of wrist irb 2400l 3hac022031-001 revision: c 100 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Removal, wrist unit the procedure below details how to remove the wrist from the robot upper arm. The wrist, which includes axes 5 and 6, is a complete unit compris...

  • Page 103

    4 repair 4.4.2. Replacement of wrist irb 2400l 101 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6. Refit the plugs. 7. Refit the cover at the motor side of axis 5-6. 8. Calibrate the robot! Calibration is detailed in a separate calibration manual, enclosed wit...

  • Page 104

    4 repair 4.4.3. Replacement of complete upper arm 3hac022031-001 revision: c 102 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.4.3. Replacement of complete upper arm location of upper arm the upper arm is located on top of the robot as shown in (a) and (b) the figure below. The complet...

  • Page 105

    4 repair 4.4.3. Replacement of complete upper arm 103 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Upper arm attachment xx0200000436 removal, upper arm the procedure below details how to remove the complete upper arm. A cover b km nuts c attachment screw d sea...

  • Page 106

    4 repair 4.4.3. Replacement of complete upper arm 3hac022031-001 revision: c 104 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, upper arm the procedure below details how to refit the complete upper arm. 8. Fit the lifting device to the upper arm, and lift enough for the strap t...

  • Page 107

    4 repair 4.4.3. Replacement of complete upper arm 105 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 10. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is incl...

  • Page 108

    4 repair 4.5.1. Replacement of complete lower arm 3hac022031-001 revision: c 106 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.5 lower arm 4.5.1. Replacement of complete lower arm location of lower arm the lower arm is located as shown in the figure below. A more detailed view of the c...

  • Page 109

    4 repair 4.5.1. Replacement of complete lower arm 107 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Removal, lower arm the procedure below details how to remove the complete lower arm. Hoisting equipment - standard toolkit the content is defined in section stan...

  • Page 110

    4 repair 4.5.1. Replacement of complete lower arm 3hac022031-001 revision: c 108 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4. Fit the lifting equipment to the lower arm to secure its weight. Xx0200000439 5. Remove the tie rod. Detailed in section removal, tie rod on page 112 . 6. Rem...

  • Page 111

    4 repair 4.5.1. Replacement of complete lower arm 109 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, lower arm the procedure below details how to refit the complete lower arm. Action note 1. Danger! Turn off all electric power, hydraulic and pneumatic...

  • Page 112

    4 repair 4.5.2. Replacement of tie rod 3hac022031-001 revision: c 110 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.5.2. Replacement of tie rod location of tie rod the tie rod is located as shown in the figure below. A more detailed view of the component and its position may be found i...

  • Page 113

    4 repair 4.5.2. Replacement of tie rod 111 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Xx0200000443 required equipment a bearing sealing b back up ring c attachment screw d locking washer e spherical roller bearing upper connection irb 2400 5 kg f bearing sea...

  • Page 114

    4 repair 4.5.2. Replacement of tie rod 3hac022031-001 revision: c 112 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Removal, tie rod the procedure below details how to remove the tie rod from the robot. Refitting, tie rod the procedure below details how to refit the tie rod to the robot....

  • Page 115

    4 repair 4.5.2. Replacement of tie rod 113 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3. Fit the new spherical roller bearings to the tie rod using the press tool, parallel bar bearing. Lubricate the bearings with bearing grease. Shown in the figure location...

  • Page 116

    4 repair 4.6.1. Replacement of smb unit 3hac022031-001 revision: c 114 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.6 frame and base 4.6.1. Replacement of smb unit location of smb unit the smb unit (smb = serial measurement board) is located on the left hand side of the base, as shown...

  • Page 117

    4 repair 4.6.1. Replacement of smb unit 115 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Smb unit, layout xx0200000452 standard toolkit the content is defined in section standard toolkit on page 178 . Circuit diagram - see chapter circuit diagram . Other tools...

  • Page 118

    4 repair 4.6.1. Replacement of smb unit 3hac022031-001 revision: c 116 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Replacement, smb unit the procedure below details how to replace the smb unit. Action note 1. Danger! Turn off all electric power, hydraulic and pneumatic pressure supplie...

  • Page 119

    4 repair 4.6.2. Replacement of brake release unit 117 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.6.2. Replacement of brake release unit location of brake release unit the brake release unit is located behind the flange plate at the robot base, as shown bel...

  • Page 120

    4 repair 4.6.2. Replacement of brake release unit 3hac022031-001 revision: c 118 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 5. Disconnect the cable from the brake release unit and remove the unit from the base. 6. Reconnect the cable to the new brake release unit and fit it to the bas...

  • Page 121

    4 repair 4.6.3. Replacement of parallel arm 119 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.6.3. Replacement of parallel arm location of parallel arm the parallel arm is located at the frame, as shown in the figure below. A more detailed view of the compone...

  • Page 122

    4 repair 4.6.3. Replacement of parallel arm 3hac022031-001 revision: c 120 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Removal, parallel arm the procedure below details how to remove the parallel arm. Assembly, parallel arm the figure below shows the assembly of the parallel arm. Xx020...

  • Page 123

    4 repair 4.6.3. Replacement of parallel arm 121 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, parallel arm the procedure below details how to refit the complete parallel arm to the robot. Action note 1. Danger! Turn off all electric power, hydraulic ...

  • Page 124

    4 repair 4.7.1. Replacement of motor, axis 1 3hac022031-001 revision: c 122 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.7 motors 4.7.1. Replacement of motor, axis 1 location of motor, axis 1 the motor, axis 1, is located on the left hand side of the robot as shown in the figure below...

  • Page 125

    4 repair 4.7.1. Replacement of motor, axis 1 123 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Required equipment note! The different motors are not compatible. Make sure to replace with correct model! Removal, motor axis 1 the procedure below details how to re...

  • Page 126

    4 repair 4.7.1. Replacement of motor, axis 1 3hac022031-001 revision: c 124 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, motor axis 1 the procedure below details how to refit the motor, axis 1. 3. Disconnect the connectors r3.Mp1 and r3.Fb1. Xx0200000401 • a: r3.Mp1 • b: r3.F...

  • Page 127

    4 repair 4.7.1. Replacement of motor, axis 1 125 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4. Fit the motor by gently lowering it straight down. Note the position of the motor! Use the mark , made on the motor base before removal. See also orientation of th...

  • Page 128

    4 repair 4.7.1. Replacement of motor, axis 1 3hac022031-001 revision: c 126 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 15. Reconnect the connectors r3.Mp1 and r3.Fb1. Xx0200000406 • a: r3.Mp1 • b: r3.Fb1 • c: connection box 16. Refit the cover of the connection box. Shown in the figur...

  • Page 129

    4 repair 4.7.2. Replacement of motor, axis 2 127 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.7.2. Replacement of motor, axis 2 location of motor, axis 2 the motor, axis 2, is located on the left hand side of the robot as shown in the figure below: xx0200000...

  • Page 130

    4 repair 4.7.2. Replacement of motor, axis 2 3hac022031-001 revision: c 128 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Required equipment note! The different motors are not compatible. Make sure to replace with correct model! Removal, motor axis 2 the procedure below details how to re...

  • Page 131

    4 repair 4.7.2. Replacement of motor, axis 2 129 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, motor axis 2 the procedure below details how to refit the motor, axis 2. 4. Remove the connection box by unscrewing its three attachment screws and plain w...

  • Page 132

    4 repair 4.7.2. Replacement of motor, axis 2 3hac022031-001 revision: c 130 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3. Fit the o-ring. Always fit a new one, see art. No. In required equipment on page 128 . 4. Fit the motor by gently lifting it straight on. Note the position of the ...

  • Page 133

    4 repair 4.7.2. Replacement of motor, axis 2 131 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 14. Perform a leak-down test. Detailed in section performing a leak-down test on page 76 . 15. Fill the gearbox with oil. Type and amount of oil is specified in secti...

  • Page 134

    4 repair 4.7.3. Replacement of motor, axis 3 3hac022031-001 revision: c 132 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.7.3. Replacement of motor, axis 3 location of motor, axis 3 the motor, axis 3, is located on the right hand side of the robot, as shown in the figure below: a more ...

  • Page 135

    4 repair 4.7.3. Replacement of motor, axis 3 133 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Required equipment note! The different motors are not compatible. Make sure to replace with correct model! Removal, motor axis 3 the procedure below details how to re...

  • Page 136

    4 repair 4.7.3. Replacement of motor, axis 3 3hac022031-001 revision: c 134 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, motor axis 3 the procedure below details how to refit the motor, axis 3. 4. Remove the connection box by unscrewing its three attachment screws and plain w...

  • Page 137

    4 repair 4.7.3. Replacement of motor, axis 3 135 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3. Fit a new o-ring to the motor. Always mount a new one, see art. No. In section required equipment on page 133 . 4. Fit the motor, by gently lifting it straight on....

  • Page 138

    4 repair 4.7.3. Replacement of motor, axis 3 3hac022031-001 revision: c 136 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 14. Perform a leak-down test. Detailed in section performing a leak- down test on page 76 . 15. Refill the gearbox with oil. Type and amount of oil is specified in se...

  • Page 139

    4 repair 4.7.4. Replacement of motors, axes 4-6, irb 2400l 137 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.7.4. Replacement of motors, axes 4-6, irb 2400l location of motors axes 4-6 the motor of axis 4 is located on the right hand side of the robot as show...

  • Page 140

    4 repair 4.7.4. Replacement of motors, axes 4-6, irb 2400l 3hac022031-001 revision: c 138 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Removal, motor axes 5-6 the procedure below details how to remove the motor, axes 5 and 6. Power supply - 24 vdc, max. 1.5 a. For releasing the brakes. ...

  • Page 141

    4 repair 4.7.4. Replacement of motors, axes 4-6, irb 2400l 139 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Removal, motor axis 4 the procedure below details how to remove the motor, axis 4. Refitting, motor axis 4 the procedure below details how to refit the ...

  • Page 142

    4 repair 4.7.4. Replacement of motors, axes 4-6, irb 2400l 3hac022031-001 revision: c 140 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 5. Fit the measuring tool at the rear of the motor. Xx0300000005 6. The motor’s fixing screws shall be fastened, but do not tighten them, to ensure that...

  • Page 143

    4 repair 4.7.4. Replacement of motors, axes 4-6, irb 2400l 141 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, motor axis 5 the procedure below details how to refit the motor, axis 5. 15. Danger! Make sure all safety requirements are met when performin...

  • Page 144

    4 repair 4.7.4. Replacement of motors, axes 4-6, irb 2400l 3hac022031-001 revision: c 142 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, motor axis 6 the procedure below details how to refit the motor, axis 6. 10. Reconnect the cabling. Described in refitting, cable harness, ax...

  • Page 145

    4 repair 4.7.4. Replacement of motors, axes 4-6, irb 2400l 143 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 7. Find the smallest play by turning the outgoing shaft for axis 4 in intervals of 90°, totally one whole turn, and thereby finding the area where the p...

  • Page 146

    4 repair 4.7.5. Replacement of motors, axes 4-6, irb 2400/10/16 3hac022031-001 revision: c 144 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.7.5. Replacement of motors, axes 4-6, irb 2400/10/16 location of motors axis 4-6 the motors axis 4-6 are located on the back of the upper arm as ...

  • Page 147

    4 repair 4.7.5. Replacement of motors, axes 4-6, irb 2400/10/16 145 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Removal, motors axes 4-6 (10/16 kg) the procedure below details how to remove the motors of axes 4-6. Power supply - 24 vdc, max. 1.5 a. For releas...

  • Page 148

    4 repair 4.7.5. Replacement of motors, axes 4-6, irb 2400/10/16 3hac022031-001 revision: c 146 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, motor axis 4 the procedure below details how to refit the motor, axis 4. 5. Remove the connection box by unscrewing its three attachment...

  • Page 149

    4 repair 4.7.5. Replacement of motors, axes 4-6, irb 2400/10/16 147 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, motor axis 5 the procedure below details how to refit the motor, axis 5. 7. In order to release the brakes, connect the 24 vdc power sup...

  • Page 150

    4 repair 4.7.5. Replacement of motors, axes 4-6, irb 2400/10/16 3hac022031-001 revision: c 148 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3. Fit a new o-ring on the motor. Spare part no. Is specified in required equipment on page 144 . 4. Fit the measuring tool at the rear of the moto...

  • Page 151

    4 repair 4.7.5. Replacement of motors, axes 4-6, irb 2400/10/16 149 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, motor axis 6 the procedure below details how to refit the motor, axis 6. Action note 1. Danger! Turn off all electric power, hydraulic a...

  • Page 152

    4 repair 4.7.5. Replacement of motors, axes 4-6, irb 2400/10/16 3hac022031-001 revision: c 150 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 11. Recalibrate the robot. (when all service work is done, i.E. The other motors are also refitted.) calibration is detailed in a separate calibrat...

  • Page 153

    4 repair 4.8.1. Replacement of gearbox, axis 1-3 151 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.8 gearboxes 4.8.1. Replacement of gearbox, axis 1-3 location of gearbox, axis 1-3 the axis 1 gearbox is located between the frame and base as shown in the figur...

  • Page 154

    4 repair 4.8.1. Replacement of gearbox, axis 1-3 3hac022031-001 revision: c 152 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Removal, gearbox axis 1-3 the procedure below details how to remove the gearbox, axis 1-3. Refitting, gearbox axis 1-3 the procedure below details how to refit th...

  • Page 155

    4 repair 4.8.1. Replacement of gearbox, axis 1-3 153 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 3. Place the gearbox unit upside-down on a table or similar surface. 4. Fit the base to the gearbox unit and secure with the 12 screws and washers. 12 pcs; m12x50...

  • Page 156

    4 repair 4.8.2. Replacement of drive shaft unit, irb 2400l 3hac022031-001 revision: c 154 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4.8.2. Replacement of drive shaft unit, irb 2400l location, drive shaft unit the drive shaft unit is defined as the gears and drive belts to axes 5 and ...

  • Page 157

    4 repair 4.8.2. Replacement of drive shaft unit, irb 2400l 155 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Removal, drive shaft unit the procedure below details how to remove the drive shaft unit from the robot upper arm. Note! Abb recommends its customers to...

  • Page 158

    4 repair 4.8.2. Replacement of drive shaft unit, irb 2400l 3hac022031-001 revision: c 156 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Refitting, drive shaft unit the procedure below details how to remove the drive shaft unit from the robot upper arm. Note! Abb recommends its customers ...

  • Page 159

    4 repair 4.8.2. Replacement of drive shaft unit, irb 2400l 157 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 12. Danger! Make sure all safety requirements are met when performing the first test run. These are further detailed in section danger - first test run ...

  • Page 160

    4 repair 4.8.2. Replacement of drive shaft unit, irb 2400l 3hac022031-001 revision: c 158 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed..

  • Page 161: 5 Calibration Information

    5 calibration information 5.1. Introduction 159 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 5 calibration information 5.1. Introduction general this chapter includes general information about different calibration methods and also details procedures that do n...

  • Page 162

    5 calibration information 5.2. Calibration methods 3hac022031-001 revision: c 160 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 5.2. Calibration methods overview this section specifies the different types of calibration and the calibration methods that are supplied from abb. Types of cal...

  • Page 163

    5 calibration information 5.2. Calibration methods 161 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Calibration methods each calibration method is detailed in a separate manual. Below is a brief description of the methods available. Calibration pendulum - stan...

  • Page 164

    5 calibration information 5.3. Calibration scales and correct axis position 3hac022031-001 revision: c 162 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 5.3. Calibration scales and correct axis position introduction this section specifies the calibration scale positions and/or correct ax...

  • Page 165

    5 calibration information 5.4. Calibration movement directions for all axes 163 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 5.4. Calibration movement directions for all axes overview when calibrating, the axis must consistently be run towards the calibration ...

  • Page 166

    5 calibration information 5.5. Updating revolution counters 3hac022031-001 revision: c 164 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 5.5. Updating revolution counters general this section details how to perform a rough calibration of each robot axis, that is updating the revolution c...

  • Page 167

    5 calibration information 5.5. Updating revolution counters 165 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 2. 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...

  • Page 168

    5 calibration information 5.5. Updating revolution counters 3hac022031-001 revision: c 166 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Step 2 - storing the revolution counter setting with the flexpendant this procedure details the second step when updating the revolution counter; stori...

  • Page 169

    5 calibration information 5.5. Updating revolution counters 167 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 4. Select the axis to have its revolution counter updated by: • ticking in the box to the left • tapping select all to update all axes. Then tap update...

  • Page 170

    5 calibration information 5.6. Checking the calibration position 3hac022031-001 revision: c 168 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 5.6. Checking the calibration position general check the calibration position before beginning any programming of the robot system. This may be do...

  • Page 171

    5 calibration information 5.6. Checking the calibration position 169 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Using the jogging window on the tpu, s4cplus this section describes how to jog the robot to all axes zero position. Using the jogging window on th...

  • Page 172

    5 calibration information 5.6. Checking the calibration position 3hac022031-001 revision: c 170 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Continued.

  • Page 173: 6  Reference Information

    6 reference information 6.1. Introduction 171 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6 reference information 6.1. Introduction general this chapter includes general information, complementing the more specific information in the different procedures in t...

  • Page 174

    6 reference information 6.2. Applicable safety standards 3hac022031-001 revision: c 172 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6.2. Applicable safety standards standards, general the robot is designed in accordance with the requirements of: • en iso 10218-1: 2006 robots for indust...

  • Page 175

    6 reference information 6.3. Unit conversion 173 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6.3. Unit conversion converter table use the table below to convert units used in this manual. Quantity units length 1 m 3.28 ft 39.37 in weight 1 kg 2.21 lb pressure...

  • Page 176

    6 reference information 6.4. Screw joints 3hac022031-001 revision: c 174 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6.4. Screw joints general this section details how to tighten the various types of screw joints on the robot. The instructions and torque values are valid for screw join...

  • Page 177

    6 reference information 6.4. Screw joints 175 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Tightening torque before tightening any screw, note the following: • determine whether a standard tightening torque or special torque is to be applied. The standard torq...

  • Page 178

    6 reference information 6.4. Screw joints 3hac022031-001 revision: c 176 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. M16 235 280 m24 790 950 ...

  • Page 179

    6 reference information 6.5. Weight specifications 177 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6.5. Weight specifications definition in installation, repair and maintenance procedures, weights of the components handled are sometimes specified. All compone...

  • Page 180

    6 reference information 6.6. Standard toolkit 3hac022031-001 revision: c 178 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6.6. Standard toolkit general all service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity. All s...

  • Page 181

    6 reference information 6.7. Special tools 179 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6.7. Special tools general all service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, d...

  • Page 182

    6 reference information 6.8. Lifting equipment and lifting instructions 3hac022031-001 revision: c 180 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 6.8. Lifting equipment and lifting instructions general many repair and maintenance activities require different pieces of lifting equipmen...

  • Page 183

    7 spare parts and exploded views 7.1. Introduction 181 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 7 spare parts and exploded views 7.1. Introduction definitions this chapter specifies all spare parts and replacement articles of the robot..

  • Page 184

    7 spare parts and exploded views 7.2. Spare parts - base 3hac022031-001 revision: c 182 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 7.2. Spare parts - base base, spare part list the spare parts for the base are listed below and shown in the figure base, spare part view on page 183 . It...

  • Page 185

    7 spare parts and exploded views 7.2. Spare parts - base 183 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Base, spare part view xx0500001610 continued.

  • Page 186

    7 spare parts and exploded views 7.3. Spare parts - lower arm 3hac022031-001 revision: c 184 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 7.3. Spare parts - lower arm lower arm, spare part list - foldout 1 the lower arm spare parts listed below are shown in foldout 1. *some of the artic...

  • Page 187

    7 spare parts and exploded views 7.3. Spare parts - lower arm 185 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. *some of the articles and spare parts are used at different locations on the robot and therefor also listed in several tables, with identical informa...

  • Page 188

    7 spare parts and exploded views 7.3. Spare parts - lower arm 3hac022031-001 revision: c 186 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. *some of the articles and spare parts are used at different locations on the robot and therefor also listed in several tables, with identical informa...

  • Page 189

    7 spare parts and exploded views 7.3. Spare parts - lower arm 187 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. *some of the articles and spare parts are used at different locations on the robot and therefor also listed in several tables, with identical informa...

  • Page 190

    7 spare parts and exploded views 7.3. Spare parts - lower arm 3hac022031-001 revision: c 188 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. *some of the articles and spare parts are used at different locations on the robot and therefor also listed in several tables, with identical informa...

  • Page 196

    7 spare parts and exploded views 7.4. Spare parts - upper arm, irb 2400/10/16 189 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 7.4. Spare parts - upper arm, irb 2400/10/16 upper arm, irb 2400/10/16, spare part list the spare parts for the upper arm, irb 2400 v...

  • Page 197

    7 spare parts and exploded views 7.4. Spare parts - upper arm, irb 2400/10/16 3hac022031-001 revision: c 190 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 39 50 g grease 3hab3537-1 40 30 ml flange sealing 12340011-116 loctite 574 41 2 sealing ring without dust lip 3hac7877-2 42 2 taper r...

  • Page 200

    7 spare parts and exploded views 7.5. Spare parts - upper arm, irb 2400/l 191 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 7.5. Spare parts - upper arm, irb 2400/l upper arm, irb 2400/l, spare part list the spare parts for the upper arm, irb 2400 version l, ar...

  • Page 201

    7 spare parts and exploded views 7.5. Spare parts - upper arm, irb 2400/l 3hac022031-001 revision: c 192 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 1 cover with lamp unit 3hac2743-1 option 39 39 torx pan head roll screw 9ada629-44 m5x12 8 40 1 cover 3hab4405-1 43 2 sealing ring (witho...

  • Page 204

    7 spare parts and exploded views 7.6. Spare parts - drive unit, irb 2400/l 193 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 7.6. Spare parts - drive unit, irb 2400/l drive unit, irb 2400/l, spare part list the spare parts for the drive unit, irb 2400 /l, are l...

  • Page 206

    7 spare parts and exploded views 7.7. Spare parts - customer cable, axis 4 3hac022031-001 revision: c 194 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 7.7. Spare parts - customer cable, axis 4 customer cable, axis 4, spare part list the spare part of the customer cable, axis 4, is liste...

  • Page 207

    7 spare parts and exploded views 7.8. Spare parts - limit switch 195 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 7.8. Spare parts - limit switch limit switch, spare part list the spare parts for the limit switch are listed below. Item qty description spare pa...

  • Page 208

    7 spare parts and exploded views 7.8. Spare parts - limit switch 3hac022031-001 revision: c 196 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed..

  • Page 209: 8 Circuit Diagram

    8 circuit diagram 8.1. Introduction 197 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. 8 circuit diagram 8.1. Introduction overview this chapter includes the circuit diagram for the robot. Continues on next page.

  • Page 210

    8 circuit diagram 8.1. Introduction 3hac022031-001 revision: c 198 © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. Continued.

  • Page 211

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 101 list of contents.

  • Page 212

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 102 connection point locations.

  • Page 213

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 103 brake unit / serial measurement board.

  • Page 214

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 104 motor axis 1 - 3.

  • Page 215

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 105 brake unit / serial measurement board.

  • Page 216

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 106 motor axis 4 - 6, 1.5 - 10 / 16.

  • Page 217

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 107 feed- back axis 4 - 6, 1.5 10 / 16.

  • Page 218

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 108 motor axis 4 - 6, 1.8 - 5.

  • Page 219

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 109 feed - back axis 4 - 6, 1.8 - 5.

  • Page 220

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 110 customer connections.

  • Page 221

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 111 integrated wirefeed cabling (option).

  • Page 222

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 112 pos. Indicator axis 1 (option).

  • Page 223

    Manipulator circuit diagram 3hac 6670-3 rev.01 product manual irb 2400 no. Of sheets 13 sheet no. 113 external connections (options).

  • Page 224

    Index 199 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. A absolute accuracy, calibration 161 attachment screws securing robot 47 b brake release unit, replacing 117 brakes releasing manually 45 testing function 27 c cabling axes 1-3, replacing 81 cabling axes 4...

  • Page 225

    Index 200 3hac022031-001 revision: c © co py rig h t 200 4- 200 8 abb. All righ ts reser v ed. O oil change gearbox axes 5-6 (wrist) 69 safety risks 37 oil in gearboxes, type and amount 68 operating conditions 41 orienting and securing robot 47 p parallel arm, replacing 119 parallel bar, replacing 1...

  • Page 227

    Abb ab robotics products s-721 68 vÄsterÅs sweden telephone: +46 (0) 21 344000 telefax: +46 (0) 21 132592 3h a c 022 031 -00 1 , r e v is ion c , en.