ABB Product Manual Procedures IRB2400 Part 2

Product manual (part 2 of 2), reference information
Articulated robot
IRB 2400 - L
IRB 2400 - 10
IRB 2400 - 16
M2000,M2000A, M2004

Product manual (part 2 of 2), reference information
Articulated robot
IRB 2400 - L
IRB 2400 - 10
IRB 2400 - 16
M2000
M2000A
M2004
Document ID: 3HAC 022031-001

Revision: A
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
ABB’s 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 Västerås
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Reference information 9
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 Standard toolkit, IRB 2400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Part list 21
3 Foldouts 23
4 Circuit diagram 25
3HAC 022031-001 Revision: A 3

Overview
Overview
About this manual

This manual contains reference information for all procedures described in the Product
manual, procedures .
Usage
This manual should be used during
• installation
• maintenance work
• repair work.
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 Contents
Reference information Useful information when performing installation, maintenance or
repair work (lists of necessary tools, reference documents, safety
standards).
Part list Complete list of manipulator parts, shown in the exploded views or
foldouts.
Exploded views / Detailed illustrations of the manipulator with reference numbers to
Foldouts the part list.
Circuit Diagram Circuit Diagram of the manipulator.
References
Reference Document Id
4 3HAC 022031-001 Revision: A

Overview
Revisions
Revision Description
- First edition.
Replaces previous manuals:
• Installation and Commssioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Model M2004 implemented.
A Section Document references is completed with article numbers for calibration
manuals.

Product documentation, M2000/M2000A
Product documentation, M2000/M2000A
General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
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 intervals)
• 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 referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual

Each hardware option for the controller 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.

Product documentation, M2004
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 given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
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 intervals)
• 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 referred 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 relevant reference
information:
• 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 it does and when it is 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
Operator’s manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
• Operator’s manual - IRC5 with FlexPendant
• Operator’s manual - RobotStudioOnline
• Trouble shooting Manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
• Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)

1 Reference information
1.1. Introduction
1.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.

1.2. Applicable Safety Standards
1.2. Applicable Safety Standards
Standards, general
The robot is designed in accordance with the requirements of:
• ISO10218, Jan. 1992, Industrial Robot Safety
• ANSI/RIA 15.06-1999
• ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing
systems - Basic requirements
• DIN 19258 - Interbus-S, International Standard
Standards, safety fence

The following standards are applicable to the safety fence surrounding the robot cell:
• ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing
systems - Basic requirements
• prEN 999:1995
Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:
• IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached
by the upper limbs.
• EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human
body.
• EN 811 Safety of machinery - Safety distance to prevent danger zones being reached
by the lower limbs.
• Pr EN 999 Safety of machinery - The positioning of protective equipment in respect
of approach speeds of the human body.
• EN 1088 Safety of machinery - Interlocking device associated with guards principles
for design and selection.

1.3. Unit conversion
1.3. Unit conversion
Converter table
Use the table below to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1L 0.264 US gal

1.4. Screw joints
1.4. Screw joints
General
This section details how to tighten the various types of screw joints on the robot and the
controller.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws

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

Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be applied. The
standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
• Use the correct tightening torque for each type of screw joint.

1.4. Screw joints
• Only use correctly calibrated torque keys.

• Always tighten the joint by hand, and never use pneumatical tools.
• Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Tightening torque (Nm)

Dimension
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Tightening torque Tightening torque Tightening torque

(Nm) (Nm) (Nm)
Dimension
Class 8.8, oil- Class 10.9, oil- Class 12.9, oil-
lubricated lubricated lubricated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
The table below specifies the recommended standard tightening torque for Molycote-
lubricated screws with Allen head screws.
Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8 28 34
M10 55 66
M12 96 115
M16 235 280

1.4. Screw joints
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
Tightening torque Tightening torque Tightening torque

Dimension
Nm - Nominal Nm - Min. Nm - Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

1.5. Weight specifications
1.5. Weight specifications
Definition
In all repair and maintenance procedures, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for
each manipulator model.
Example
Below is an example of how a weight specification is presented:
CAUTION!
Caution!
The motor weighs 32 kg! All lifting equipment used must be sized accordingly!

1.6. Document references
General
The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced
documentation.
Product specification, robot

The product specification includes generic technical data. The specification listed below is
the English version.
Document name Document ID

Product specification 3HAC 9112-1
Product manuals, controller

The product manuals include information about installation and service activities. The table
below specifies the article numbers of the product manuals for all controller models. The part
number -001 is the English version.
Document name Document ID

Product manual, S4Cplus M2000 3HAC 021333-001
Product manual, S4Cplus M2000A 3HAC 021128-001
Product manual, IRC5 M2004 3HAC 021313-001
Operators manual
The operators manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operators manuals for different robot systems.
Document name Document ID Note

User’s guide (S4Cplus) 3HAC 7793-1 Contains instructions for daily operation
of S4Cplus based robot systems.
Operator’s manual (IRC5) 3HAC 16590-1
Calibration manuals

Calibration Pendulum 3HAC 16578-1 Enclosed with the Calibration
Instruction Pendulum Toolkit.
Instructions for Levelmeter 3HAC 022907-001 Enclosed with the Levelmeter 2000.
calibration (alternative method)
CalibWare 2.0 Users Guide 3HAC 16090-1 Calibration tool for Absolute
Accuracy calibration.

Additional documentaion

External axes 3HAC 9299-1

1.7. Standard toolkit, IRB 2400
1.7. Standard toolkit, IRB 2400
General
All service (repair, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. All special tools, i.e. all tools that are not considered
standard as defined below, are listed in their instructions respectively.
This way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents
Qty Tool
1 Ring-open-end spanner 8-19mm
1 Socket head cap 2,5-17mm
1 Torx socket no:20-60
1 Torque wrench 10-100Nm
1 Small screwdriver
1 Ratchet head for torque wrench 1/2
1 Socket head cap no:5, socket 1/2"" bit L 20mm
1 Small cutting plier

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


2: Part list
2.0.1 Introduction
Definitions This chapter is an appendix to the manual and contains part lists for the manipulator. The item
numbers refers to chapter Foldouts on page 35.
The part list for the manipulator sometimes differ between robot versions.

2.0.2 Foot
Foot Item number refers to item number on the foldouts.Customer cable
Itm Qty Name Art. No. Remarks

1 1 Foot 3HAC 5945-1
2 1 Gear box axes 1-3 3HAC 4795-1
3 12 Hex socket head cap screw 3HAB 3402-69 M12x50 8.8 Gleitmo 610
Gleitmo 610
4 12 Plain washer 9ADA 312-9 13x24x2.5
5 2 Motor axes 1 and 3 3HAC 4789-1
2 Motor axes 1 and 3 3HAC 021346-001 5/10/16/kg, Yaskawa
1 Motor axes 1 3HAC 021961-001 Wall ,Yaskawa
6 3 O-ring 2152 2012-434 109.5x3
7 12 Spring washer 2154 2033-9 8.4x18x2
Axis 4Lower arm
Itm Qty Name Art. No. Remarks

1 Customer cable extension, axis 4 3HAC 8869-1 Option 043
See below
2400L/10, /16Upper Arm IRB 2400/10/16
Itm Qty Name Art. no. Remark

1 Lower arm 3HAC 4796-1 2400/10, /16
1 Lower arm 3HAC 4797-1 2400L
11 8 Spring washer 2154 2033-10 10.5x23x2.5
12 12 Hex socket head cap screw 3HAB 3409-50 M10x40 12.9
13 1 Spring tension plate 3HAC 2205-1 66x116x3
14 1 Damper, standard axis 2 3HAC 2180-1
15 1 Damper axis 3 3HAB 5512-1
16 4 Torx pan head roll. screw 9ADA 629-56 M6x16


18 1 Parallel arm 3HAB 9394-1
19 2 Sealing ring 3HAB 3732-13 V-110-L 99x10.5
20 1 Groove ball bearing 3HAB 3643-12 61822-2RS1
21 2 Sealing ring 3HAB 5515-1 Acetal
26 2 Hex socket head cap screw 9ADA 183-34 M8x12
32 1 Sealing 3HAC 10089-2
33 1 Locking washer 3HAB 5523-1 SS 1914-04
34 1 Hex socket counters, head 2121 2852-449 M8x16 8.8
35 1 Sealing 3HAC 10088-4 Acetal (POM)
36 1 Motor axis 2 3HAC 4790-1
1 Motor axis 2 3HAC 021350-001 5/10/16/kg, Yaskawa
41 Lubricating oil 1171 2016-604 14 700 ml
42 Bearing grease 3HAB 3537-1 1g
43 Locking liquid 3HAB 7116-1 1 ml Loctite 243
46 1 Stop axis 1 3HAB 6687-1
48 6 Washer 2151 2082-150 6.1x20x2
49 1 Friction washer 3HAC 0447-1
50 1 Sync. mark. axis 2 3HAB 5522-1
51 1 Upper arm axes 4-6
54 2 Lock nut 2126 2851-107 M35x1.5
55 2 Shaft end 3HAB 5527-1 SS 1672-08
57 2 VK-cover 3HAA 2166-15 VK 62x8
60 1 Sync. market axis 3 3HAB 8385-1
62 2 Washer 3HAA 1001-134
63 9 Torx pan head roll screw 9ADA 629-43
100 1 Cable unit axes 1-3 3HAC 4791-1
102 1 Bottom plate 3HAC 2828-1
103 1 Gasket 3HAC 4554-1
104 1 Cover 3HAC 9368-1 Standard
104 1 Cover 3HAC 9362-1 Foundry
104 1 Cover 3HAC 7242-1 Wire feeder
105 1 Gasket 3HAC 3200-1
107 1 Bracket 3HAB 5923-1
108 2 Holder for cable guide 3HAB 3299-1
109 1 Cable guide 3HAB 5924-1
110 1 Spring 3HAB 3662-1
111 1 Cable guide upper arm 3HAB 5928-1 IRB 2400/10/16
112 3 Cover 3HAC 4337-1
114 1 Instruction plate 3HAC 2589-1
115 1 Serial meas. board 3HAB 3700-1


117 1 Battery unit 4944 026-4
118 14 Hexagon nut with flange 9ADA 290-1 M5 fzb
119 12 Cable straps, outdoor 2166 2055-3 L=208 mm
121 1 Push button unit 3HAC 0017-1
122 4 Distance bolt 2125 2052-198 M5x15
123 1 Push button cover 3HAC 2744-1
125 1 Cable straps, outdoors 2166 2055-7 8.9x780
129 1 Signal cable SMB 3HAC 7819-1
132 2 Dust cap 3HAC 7561-3
133 1 Dust cap 3HAC 7561-4
134 15 Torx pan head screw 9ADA 618-56 M6x16 8.8
135 3 Hex socket head pan screw 9ADA 183-34 M8x12 8.8
136 8 Torx pan head roll. screw 9ADA 629-34 M4x12 Ext. conn.
138 6 Cable straps, outdoors 2166 2055-1 L=101 mm
139 1 Coupling 3HAB 3333-20
140 Locking liquid 1269 0014-412 Loctite 542
141 2 Protective hood 2522 2101-8 D=11.4 - 13
147 3 Gasket 3HAC 4419-1
149 1 Gasket 3HAB 7160-1
150 Flange sealing 1234 0011-116 Loctite 574
151 Adhesive tape 1169 9198-301 19x0.18
152 1 Bracket 3HAB 5921-1
156 1 Parallel pin 3HAC 3785-1
157 1 Adaptor, customer cabling 3HAB 7328-1
157 1 Cover protection 3HAC 6823-1
158 1 Adaptor, power cabling 3HAB 2809-1
159 2 Protection cover 3HAC 7816-1 Foundry
168 1 Protective hood 3HAC 3189-1 Suspended
169 2 Gasket 3HAB 9040-1 Standard
170 1 Cover 3HAC 0048-1
171 Profile 1866 1903-1 120 mm
Axes 4-6Upper Arm IRB 2400L

47 1 Bracket 3HAC 0001-1
49 1 Hex socket counters, head 2121 2852-449 M8x16 8.8


50 1 Locking washer 3HAB 5523-1 SS 1914-04
51 Locking liquid 3HAB 7116-1 6 ml, Loctite 243
52 3 Gasket 3HAC 4429-1
54 9 Torx pan head screw 9ADA 618-46 M5x20 8.8
56 Adhesive tape 1169 9198-301 500 mm, 19x0.18
57 1 Cover 3HAB 6491-1
57 1 Cover with lamp unit 3HAC 2774-1
60 1 Motor unit axis 6 3HAC 10602-2
1 Motor unit axis 6 3HAC 021731-001 10/16 kg, Yaskawa
1 Motor unit axis 6 3HAC 021741-001 5 kg, Yaskawa
1 1 Upper arm without wrist and 3HAC 1581-1
motors
13 4 Disc spring 3HAB 3731-14 67.5x50.5x0.7
18 1 Wrist 3HAB 9439-1 Standard
18 1 Wrist 3HAB 9398-1 Foundry
19 1 O-ring 3HAB 3772-12 Nitrile rubber 126x4
Gleitmo 610
21 15 Plain washer 9ADA 312-7 8.4x16x1.6
25 1 Motor unit axis 5 3HAC 10600-1 10 kg
1 Motor unit axis 5 3HAC 10601-1 16 kg
Motor unit axis 5 3HAC 021722-001 10/16 kg, Yaskawa
26 2 Motor unit axis 4 3HAC 10602-1
2 Motor unit axis 4 3HAC 021353-001 10/16 kg, Yaskawa
27 3 O-ring 3HAB 3772-1 Nitrile rubber
34.2x3
Gleitmo 610
Gleitmo 610
33 Lubricating oil 3HAC 0860-1 2300 ml
34 2 Magnetic plug 2522 122-1 R1/4”
35 2 Sealing ring 2152 2031-6
39 Bearing grease 3HAB 3537-1 50 g
40 Flange sealing 1234 0011-116 30 ml, Loctite 574

41 2 Sealing ring without dust lip 3HAC 7877-2
42 2 Taper roller bearing 3HAA 2103-15 32007 X
43 1 Parallel bar 3HAC 1564-1
44 2 Spherical roller bearing 3HAA 2167-12 22206 CC
PartsDrive unit IRB 2400/10/16

1 1 Tubular shaft 3HAC 0235-1
2 1 Back-up ring 3HAB 6354-1
3 1 Sealing ring 3HAB 3732-13 99x10.5
V-110-L
4 2 Ball bearing 2213 253-12 105x130x13
61821-2RSI
5 2 Cover plug 2216 264-14 IRB 2000
6 1 Housing, axis 4 3HAC 0236-1
7 2 Spacer 2159 167-61 D=115/105,
T=0.05
8 4 Spacer 2159 167-62 D=115/105,
T=0.1
9 1 Spacer 2159 167-63 D=115/105,
T=0.5
10 1 Gear, axis 4, step 2 3HAB 3210-1
11 1 Damper, axis 4 3HAB 6356-1
Gleitmo 610
A2F
14 4 Hex socket head cap screw 3HAB 3402-30 M6x45 8.8,
Gleitmo 610
Drive unit axis 5-6Drive unit IRB 2400L

Polyamide 6.6
black
46 1 Clamp 2166 2018-8 D=6
5562-00-04
47 1 Clamp 2166 2018-2 D=11
5562-00-07
48 1 Bracket, axes 5-6 3HAB 3230-1
49 2 Torx pan head roll screw 9ADA 629-47 M5x25 8 A2F
50 1 Parallel bar 3HAC 1563-1
51 1 Damper, axis 3 3HAB 5511-1

52 2 Hex socket head cap screw 9ADA 183-22 M6x10 8.8
A2F
53 2 Spherical roller bearing 3HAA 2167-12 D=30/62 W=20
22206 CC
Standard
56 1 Locking washer 3HAA 2356-11 9x35x3
Gleitmo 610
58 1 Cable bracket upper arm 3HAB 5927-1
59 1 Cable unit axes 4-6 3HAC 13052-1 Wire feeder
60 3 Gasket 3HAB 4429-1
61 1 Cable straps, outdoors 2166 2055-3
15 1 Drive unit axis 5-6
16 1 Motor unit, axis 4 3HAC 11864-1
17 4 Hex socket head cap screw 9ADA 183-14 M5x16 8.8, A2F
18 1 O-ring 2152 2011-414 44.2x3, Nitrile
rubber
23 1 Gear unit, axis 4 3HAB 3380-1
24 2 Plain washer 9ADA 312-7 8.4x16x1.6, A2F
25 2 Hex socket head cap screw 9ADA 183-38 M8x30 8.8, A2F
28 1 Cover 3HAB 6355-1
30 Lubricating oil 1171 2016-604 30 ml
31 Locking liquid 3HAB 7116-1 Loctite 243
32 Locking liquid 1269 0014-413 Loctite 638
34 Flange sealing 1234 0011-116 Loctite 574
35 Bearing grease 3HAB 3537-1 Shell Retinax MS
36 1 Wrist, 5 kg 3HAC 10814-1 Standard and
Foundry
37 6 Hex socket head cap screw 3HAB 3402-25 M6x20 8.8,
Gleitmo 610
38 1 Cover 3HAB 4350-1
1 Cover with lamp unit 3HAC 2743-1 Option
39 39 Torx pan head roll screw 9ADA 629-44 M5x12 8
40 1 Cover 3HAB 4405-1
43 2 Sealing ring (without dust lip) 3HAB 7877-2 D=42/55 W=8
Nitrile rubber
44 2 Taper roller bearing 3HAA 2103-15 D=35/62 W=18
32007 X

Axes 5-6Limit Switch

1 1 Drive shaft unit, axes 5-6 3HAC 11804-1
2 2 Motor unit axes 5-6 3HAC 11865-1
3 1 Motor plate 3HAA 2504-1
4 8 Hexagon nut 9ADA 267-5 M5 8. A2F
Gleitmo 610
6 10 Plain washer 9ADA 312-5 5.3x10x1. A2F
7 2 Gear belt 3HAA 2393-1
Axis 1

3 Switches
1 2 Holder ring 3HAC 0305-1
2 6 Hexagon screw, button head 3HAC 0596-31 M8x12
3 7 Cam, blank 3HAB 8086-1
4 24 Torx pan head screw 9ADA 618-55 M6x12
5 1 Attachment plate 3HAC 0982-1
6 2 Torx pan head screw 9ADA 618-56 M6x16
7 0 Position switch 1 3HAC 6447-1
7 1 Position switch 1-3 3HAC 6448-1
9 9 Shims-sheet 3HAB 7478-1
11 6 Clamp 2166 2018-9 D=8
13 1 Assembly instruction 3HAB 8372-1 Incl. in the
delivery.
14 2 Torx pan head screw 9ADA 618-59 M6x30.

3 Foldouts
3 Foldouts

3 Foldouts

4 Circuit diagram
4 Circuit diagram

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

CONNECTION POINT LOCATIONS

BREAK UNIT

MOTOR AXIS 1 - 3

SERIAL MEASUREMENT BOARD

MOTOR AXIS 4 - 6, 1.5 - 10 / 16

FEED- BACK AXIS 4 - 6, 1.5 10 / 16

MOTOR AXIS 4 - 6, 1.8 - 5

FEED - BACK AXIS 4 - 6, 1.8 - 5

CUSTOMER CONNECTIONS

INTEGRATED WIREFEED CABLING (OPTION)

POS. INDICATOR AXIS 1 (OPTION)

EXTERNAL CONNECTIONS (OPTIONS)

3HAC 022031-001, Revision A, en

ABB Automation Technologies AB
Robotics
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592

ABB Product Manual Procedures IRB2400 Part 2

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ABB Product Manual Procedures IRB2400 Part 2

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Product manual (part 2 of 2), reference information

Document ID: 3HAC 022031-001

© Copyright 2004 ABB All right reserved.

3HAC 022031-001 Revision: A 3

About this manual

Who should read this manual?

4 3HAC 022031-001 Revision: A

3HAC 022031-001 Revision: A 5

Product documentation, M2000/M2000A

Controller hardware option manual

6 3HAC 022031-001 Revision: A

Product documentation, M2004

3HAC 022031-001 Revision: A 7

• How to use the application

8 3HAC 022031-001 Revision: A

3HAC 022031-001 Revision: A 9

1.2. Applicable Safety Standards

Standards, safety fence

Standards, robot cell

10 3HAC 022031-001 Revision: A

1.3. Unit conversion

3HAC 022031-001 Revision: A 11

1.4. Screw joints

Gleitmo treated screws

Screws lubricated in other ways

Lubricant Art. no.

12 3HAC 022031-001 Revision: A

• Only use correctly calibrated torque keys.

Tightening torque (Nm)

Tightening torque Tightening torque Tightening torque

Tightening torque (Nm) Tightening torque (Nm)

3HAC 022031-001 Revision: A 13

Tightening torque Tightening torque Tightening torque

14 3HAC 022031-001 Revision: A

1.5. Weight specifications

3HAC 022031-001 Revision: A 15

1.6. Document references

Product specification, robot

Document name Document ID

Product manuals, controller

Document name Document ID

Document name Document ID Note

Document name Document ID Note

16 3HAC 022031-001 Revision: A

Document name Document ID Note

3HAC 022031-001 Revision: A 17

1.7. Standard toolkit, IRB 2400

18 3HAC 022031-001 Revision: A

1.8. Lifting equipment and lifting instructions

3HAC 022031-001 Revision: A 19

20 3HAC 022031-001 Revision: A

3HAC 022031-001 Revision: A 21

Foot Item number refers to item number on the foldouts.Customer cable

Itm Qty Name Art. No. Remarks

Axis 4Lower arm

Itm Qty Name Art. No. Remarks

2400L/10, /16Upper Arm IRB 2400/10/16

Itm Qty Name Art. no. Remark

22 3HAC 022031-001 Revision: A

Itm Qty Name Art. no. Remark

3HAC 022031-001 Revision: A 23

Itm Qty Name Art. no. Remark

Axes 4-6Upper Arm IRB 2400L

Itm Qty Name Art. no. Remark