Service Manual: Publ - No.: 3HNT 02330-1 en Rev.03

Service Manual
IRB 5400-02
Publ.No.: 3HNT 02330-1 en Rev.03
ABB AS, Robotics

The information in this document 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 document.
In no event shall ABB be liable for incidental or consequential damages arising from use of this document or of the
software and hardware described in this document.
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third
parties without express authority is strictly forbidden.
Additional copies of this document may be obtained from ABB at its then current charge.
© 2004-2006 ABB AS, Robotics
ABB AS, Robotics

Automation Technology Products Division
Bryne - Norway
First Edition: 10 June 2004

Table of Contents
Service Manual
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Description of Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Motor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Component Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Releasing Axis Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Mounting Instructions for Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Mounting Instructions for Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Instructions for Tightening Screw Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Oil Type Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5 Lubricate Hollow Wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.6 Lubricate Balancing Transmission Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.7 Lubricate Balancing Spring Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.8 Check Oil Level in Gear Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.9 Measuring System Battery - Non-Ex / Old Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 Base Unit Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1 Removal of Motor for Axes 1, 2, 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 Installation of Motor for Axes 1, 2, 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3 Disengage Balancing Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4 Engage Balancing Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5 Removal of Balancing Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.6 Installation of Balancing Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.7 Adjusting Balancing Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.8 Removal of Bearings in Connection Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.9 Installation of Bearings in Connection Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.10 Removal of Balancing System Crank Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.11 Installation of Balancing System Crank Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.12 Removal of Balancing System Lever Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.13 Installation of Balancing System Lever Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.14 Removal of Axis 1 Main Shaft Gearbox Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3HNT 02330-1 en Rev.03 3

4.15 Installation of Axis 1 Main Shaft Gearbox Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.16 Removal of Axis 2 and 3 Main Shaft Gearbox Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.17 Installation of Axis 2 and 3 Main Shaft Gearbox Seal . . . . . . . . . . . . . . . . . . . . . . . . . 65
5 Vertical Arm Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.1 Removal of Upper Bevel Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.2 Installation of Upper Bevel Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.3 Removal of Vertical Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.4 Installation of Vertical Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.5 Removal of Axis 3 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.6 Installation of Axis 3 Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.7 Removal of Lower Bevel Gear Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.8 Installation of Lower Bevel Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6 H10 Horizontal Arm Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

6.1 Removal of Horizontal Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.2 Installation of Horizontal Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.3 Removal of Horizontal Arm Drive Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.4 Installation of Horizontal Arm Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.5 Removal of Motor for Axes 4, 5, 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.6 Installation of Motor for Axes 4, 5, 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.7 Removal of Wrist Transmission Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.8 Installation of Wrist Transmission Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7 H40 Horizontal Arm Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

7.1 Removal of Horizontal Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.2 Installation of Horizontal Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.3 Removal of Horizontal Arm Drive Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.4 Installation of Horizontal Arm Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.5 Removal of Motor for Axes 4, 5, 6 and Pump Motor 1, 2 . . . . . . . . . . . . . . . . . . . . . . . 118
7.6 Installation Motor for Axes 4, 5, 6 and Pump Motor 1, 2 . . . . . . . . . . . . . . . . . . . . . . . 120
7.7 Removal of Wrist Transmission Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.8 Installation of Wrist Transmission Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.9 Removal of Function Valve Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.10 Installation of Function Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.11 Removal of Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.12 Installation of Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
8 Hollow Wrist Unit Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

8.1 Removal of Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
8.2 Installation of Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
8.3 Removal of Wrist Inner Flexible Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
8.4 Installation of Wrist Inner Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8.5 Replacing Wrist Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
9 Oil Change in Gear Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

9.1 Replace Oil for Axes 1, 2, 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4 3HNT 02330-1 en Rev.03

9.2 Replace Oil in Bevel Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
9.3 Replace Oil for Axes 4-6 - Hollow Wrist Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10 Replacing Cable Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

10.1 Removal of Cables Foot Unit - Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
10.2 Installation of Cables Foot Unit - Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.3 Removal of Cables Base Unit - Vertical Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.4 Installation of Cables Base Unit - Vertical Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.5 Removal of Cables Vertical - Horizontal Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.6 Installation of Cables Vertical - Horizontal Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
11 Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

11.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
11.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
11.3 Calibrating the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
11.4 Updating Revolution Counters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
11.5 Check Calibration Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
12 Calibration Fixture Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

12.1 Calibration Fixture Installation, Axes 1,2,3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
12.2 Calibration Fixture Installation, Hollow Wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
13 Reference Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3HNT 02330-1 en Rev.03 5

6 3HNT 02330-1 en Rev.03
Introduction
Service Manual
This manual provides information and instructions for replacing parts and performing
preventive maintenance on the IRB 5400-02 robot.
WARNING!
Before performing any work described in this manual, the Safety Manual and
’Safety Guidelines’ on page 7 must be read and understood. Work must only be
performed by skilled personnel with the proper training.
1 Introduction
Introduction includes general information and safety considerations concerning the use
of this manual.
1.1 Safety Guidelines
WARNING!
Following safety precautions concerning the work described in this manual must be
read before starting to work on the robot.
No work must be performed on the robot unless the area where the robot is located
is free from explosive gases.
Some of the manipulator components are heavy. Proper lifting device must be used
whenever required.
All motors on the robot can be very hot. Make sure that the motors are allowed to
cool down before touching them.
When work is done on the robot signal cabling, this may result in the robot moving
to incorrect positions. After doing such work, it is important that the robot
calibration position is checked. If a calibration fault is discovered, the robot must be
re-calibrated.
When service work is finished, the calibration position should always be checked
with the system disc.
Due to the hazard with the balancing springs, all work described in this manual
must be performed exactly as described in the procedures.
Axis brakes must NEVER be released before having read the safety precautions
under ’Releasing Axis Brakes’ on page 11.
Removing an axis motor will disengage the brake function. For this reason, the
motor for axis 2 and/or 3 must never be removed while other repair work is being
performed. No other repair work must be performed if one or both of these motors
are removed.
Service Manual 3HNT 02330-1 en Rev.03 7

Introduction
1.2 Description of Publication

The manual includes information on how to replace different components on the robot.
The procedures are divided into a procedure for removal and a procedure for installation.
At the start of each procedure a reference list shows information located other places in
the manual than in the procedure. If you want to print out a procedure you should also
print the information referred to under reference to get all information you need to
perform the repair operation.
The manual describes the type of service work that can be carried out by the Customer´s
own service staff on site. Certain types of work, requiring special experience or special
aids, are not dealt with in the manual. In such cases, the defective module or component
should be replaced on site. The faulty item should be sent to ABB AS, Robotics, for
service.
1.3 General Information

Following points should be observed when using this manual.
Replacement Items
Make sure that any replacement items are available before performing any repair
procedures. Use only replacement items listed in the spare parts catalogue.
Over Pressure
During operation, the manipulator is supplied by an over-pressure (ex-version). For this
reason, the robot can not operate unless all panels are in place and properly sealed.
Missing screws will cause air leaks and result in increased air consumption or failure in
the over-pressure system. This does not apply for non-ex robots.
Tools
Most of the repair work on the robot can be performed with normal hand tools. A few
special tools are however required. These tools will be stated in the procedures where
they are needed. For information on available special tools, see ’Special Tools’ on page
12.
Illustration References
References to illustrations are placed in brackets ( ) indicating figure number and
position in the figure. Example: (15/3) means figure 15 position 3.
Identification Labels
The manipulator and other robot components are equipped with identification labels. For
location of these labels, see ‘Installation and Commissioning’ manual.
8 3HNT 02330-1 en Rev.03 Service Manual

Introduction
1.4 Calibration
Re-calibration of the robot must be performed after replacing mechanical parts, when a
resolver error has occurred or when the power supply between a measurement board and
resolver has been interrupted etc.
Calibrating the robot means to place the robot arm and wrist in a specific position. To
place the arm and wrist in this position, a calibration fixture must be available. For
information on the calibration fixture, see ’Special Tools’ on page 12.
Calibration is performed as described in chapter ’Calibration Procedure’ on page 173.
Installation of calibration fixture is described in chapter ’Calibration Fixture Installation’
on page 181.
1.5 Motor Units

Each axis of the manipulator has its own electric motor unit, including a synchronous
motor, a brake and a feedback device (resolver). Different motors are used for different
axes on the robot. The drive shaft of the motor forms a part of the gearbox of the
manipulator axis.
The axis motor has a built-in brake called axis brake. The brake is holding the motor (the
brake is ‘on’) when no power is applied to the motor and brake. When the motor is
switched ‘on’, 24VDC is simultaneously applied to the brake, and the brake is released
(brake is ‘off’).
Note. A system parameter called ‘brakes on time’ is available. This parameter can be
used to switch ‘off’ the servo motors and engage the brake (brake ‘on’) after the robot
has been idle for a period of time. This parameter is normally not used for painting
robots and is therefore set to maximum time by default.
The feedback device and brakes are installed by the supplier of the motor and should
never be removed from the motor. The complete motor assembly should be replaced as a
complete unit.
The motor does not need to be commutated (commutation value is 1.570800).

Introduction
1.6 Component Overview

The illustration below shows the robot type and components included in this manual.
Figure 1 Component identification
Horizontal arm, H40 (process arm)

Motor 4, 5, 6
Upper bevel gear

Hollow wrist
Horizontal arm, H10
Vertical arm, V11 Vertical arm, V12

(Old style) (New style)
Lower bevel gear
Motor 1
Base unit, B10
Motor 3 (Motor 2
on opposite side)
Foot unit
Riser foot unit

Introduction
1.7 Releasing Axis Brakes

The axis brakes need to be released in many cases during repair work to reposition the
robot arm. A complete description of the different methods for releasing the brakes is
available in the ‘Installation and Commissioning’ manual. The following describes how
to release the brakes in a common connector in the foot unit or directly on the axis
motors.
WARNING!
Always stay clear of the robot arm and wrist and/or make sure that the arm and
wrist are properly suspended before releasing the axis brakes. Releasing the brakes
may cause the robot arm and wrist to drop or raise, depending on the weight (paint
equipment) installed on the arm and the tool installed on the wrist.
When the manipulator is not fastened to the floor, it is not stable in the whole
working area. When the arms are moved, care must be taken to prevent the
manipulator from tipping over. Not paying attention to this hazard can cause severe
injuries to personnel or equipment.
Make absolutely certain that no personnel is working on the robot or control system
when moving the robot arm by hand. Moving the electric motors will generate
400VAC which will be present in the robot and control system.
Axis brakes must not be released if balancing system is inoperative unless the robot
arm and wrist are properly suspended.
To release the brakes, a 24 VDC power supply capable of supplying minimum 4 Ampere
must be available.
Figure 2 Brake release connections on motor connectors
3 1 3 1 3 1
0 Volt
+24VDC
4
8 7 +24VDC 8 7 +24VDC
9
12 X12 12 0 Volt
15 X2 (old style) 0 Volt Alt. 1 - Individual motor connector
4 1 Motor:
+24VDC
7 6 4
0 Volt
+24VDC
15 14 5
0 Volt
+24VDC
23 22 6
24 0 Volt
Foot unit Alt. 2 - Common motor connector
Releasing brakes for all motors Releasing brakes for motor 1, 2, 3 Releasing brakes for motor 4, 5, 6
To release the brakes for all axes simultaneously, connect +24VDC and 0 Volt to
connector X2 in the manipulator foot unit as shown at the left in the figure above.
To release the brakes for a single motor, connect +24VDC and 0 Volt directly to the
motor connector as shown at the right in the figure above.

Introduction
1.8 Special Tools
Guiding Bolt Tool

Use: IRB 5400-0x
Part no.: 3HNM 00835-1
Required for engaging, disengaging and adjusting balancing
springs for axis 2 and 3.
Rotor Rotating Tool

Use: All robot types
Required for rotating axis motor during motor alignment.
Calibration Fixture Kit

Use: All robot types
Part no.: Depends on robot type, see ‘Product Specification’
manual.
Required for calibration of the robot. Different fixtures are required
for different robot models.
Valve and Spring Cover Pin Wrench

Use: Paint system service
Used for removal and installation of 2/2 fluid valve in color changer.
Purge System Bypass Switch (Purge Link)

Use: S4P+ Control Cabinet
Part no.: 3HNE 09358-1
Used to bypass purge system for service purposes, i.e. to be able
to apply power to the manipulator with panels removed.
USE ONLY FOR SERVICE
Cable RS422 CNV Debug PC

Use: S4P and S4P+ Control Cabinet
Part no.: 3HNE 01659-1
Cable for converting RS422 to RS232. Used to connect a PC to the
AMA module (and S4P ACA) for debugging purposes.

General Information
2 General Information
The following sections provide general information on handling of bearings and seals,
tightening screws, list of special tools etc.
2.1 Mounting Instructions for Bearings
2.1.1 General
• Let a new bearing remain in its wrapping until it is time for fitting, to avoid
contamination of the bearing.
• Ensure that all parts included in the bearing fitting are free from burrs, grinding waste
and other contamination. Cast components must be free from foundry sand.
• Bearing rings, inner rings and roller elements must under no circumstances be
subjected to direct impact. Also, the roller elements must not be exposed to any
stresses during the assembly work.
2.1.2 Tapered Bearings

• The bearing should be tensioned gradually until the recommended pre-tension is
achieved.
• It is important to note that the roller elements must be rotated a specified number of
turns before pre-tensioning is carried out, and also rotated during the pre-tensioning
sequence.
• The above procedure must be carried out to enable the roller elements to adjust to the
correct position against the race flange. Also, it is important that the bearing is
properly aligned, as this will directly affect the lifespan of the bearing.
2.1.3 Greasing Bearings

• The bearing must be greased after fitting. The main reason for this is the requirement
for cleanliness. Good quality lubricating grease should be used.
• Grooved ball bearings should be filled with grease from both sides.
• Tapered roller bearings and axial needle bearings shall be greased in the split
condition.
• The bearings must not be completely filled with grease.
• During operation, the bearing should be filled to 70-80% of the available volume.
• Ensure that grease is handled and stored properly, to avoid contamination.

General Information
2.2 Mounting Instructions for Seals
2.2.1 General
• A common cause of leakage is incorrect fitting.
2.2.2 Rotating Seals

• The sealing surfaces should be protected during transport and mounting.
• The seal should be kept in the original wrappings or otherwise be well protected.
• Sealing surfaces must be inspected before mounting. Scratches or damage of surface
may result in future leakage, the seal must be replaced.
• Seals should also be checked before mounting to ensure that:
– there is no damage to the sealing edge (feel with a fingernail)
– the seal is of the correct type (provided with cutting edge)
– there is no other damage
• Grease the seal just before fitting it, but not too early as there is a risk of dirt and
foreign particles adhering to the seal. The space between the dust tongue and sealing
lip should be filled to 2/3 with grease. The rubber coated external diameter must also
be greased.
• The fitting of seals and gears must be carried out on a clean workbench.
• Mount the seal correctly. If it is misaligned, there is a risk of leakage due to the
pumping effect.
• Always mount the seal with a mounting tool. Never hammer directly on the seal, as
this may result in leakage.
• Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
keyways, etc.
2.2.3 Flange Seals and Static Seals

• Check the flange surfaces. They must be even and free from pores. It is easy to check
smoothness using a gauge on the fastened joint (without sealing compound).
• Differences in surface level or the presence of burrs due to incorrect machining are
not permissible. If flange surfaces are defective, the parts must not to be used, because
leakage could result.
• The surfaces must be properly cleaned.
• Distribute the sealing compound evenly over the surface, preferably with a brush.
• Tighten the screws evenly when fastening the flange joint.

General Information
2.2.4 O-rings
• Check the O-ring grooves. The grooves must be geometrically correct and free from
pores and contamination.
• Check the O-ring with regard to surface defects, burrs, shape accuracy, etc.
• Ensure that the correct O-ring size is used.
• Tighten the screws evenly when assembling.
• Defective O-rings must not be used.
• O-ring groove must have no damage.
• Fitting defective parts will result in leakage. Grease the O-ring before mounting.

General Information
2.3 Instructions for Tightening Screw Joints
2.3.1 General
It is of the utmost importance that all screw joints be tightened with the correct torque.
2.3.2 Tightening Torques

The following tightening torques are to be used for all screw joints in metallic materials
unless otherwise specified in the text.
These instructions do not apply to screw joints comprising soft or brittle materials.
All screws on the robot except for adjusting screws should be tightened with torque
according to Table 1 on page 16 and Table 2 on page 16 unless otherwise specified.
Galvanized screws are of 8.8 quality and untreated screws (black oxide) are of 12.9
quality. Torques apply to lightly lubricated screws.
Table 1 Torque table, screws with hexagon socket head
Screw quality
Nominal 8.8 12.9
Diameter Nm Nm
M4 2.9 4.9
M5 5.9 10.0
M6 9.9 16.5
M8 24.0 40.0
M10 47.0 79.0
M12 82.0 140.0
M14 130.0 220.0
M16 200.0 340.0
Table 2 Torque table, screws with slotted or cross recessed head

Nominal Tightening torque - Nm
Diameter class 4.8 “Dry”
M 2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
2.3.3 Using Loctite

Do not use Loctite where it is not specified.
Loctite 243 Glue (Blue)
Add a drop of Loctite 243 to screws which you can see have Loctite when dismounted
(old designation 242).

General Information
Loctite 2701 Glue (Green)

Must be used on screws where it is especially important that the screws are firmly fixed.
Screws with green Loctite are much harder to open than screws with blue Loctite. It may
be required to heat screws to be able to loosen! (Old designation 270).
Do not use Loctite on following:
Hexagon socket head cap screws (guide screws) with grounded cylindrical stem
BS 4168 - ISO 7379, and all swivels.
Loctite 574 - Liquid gasket
Loctite 574 or equivalent must be used whenever liquid gasket is specified in the
procedures.
Loctite 5221 - Sealing glue
Loctite 5221 must be used whenever sealing glue is specified in the procedures.

General Information
2.4 Oil Type Specifications

The gearboxes in the robot are filled with Shell Omala 320 before shipment. The oil
types shown in the tables below can be used as substitutes for this oil.
Mineral oils and greases recommended by the oil suppliers:
Ambient temperature: Minimum 0°C, maximum 70°C
Table 3 Oil type standards
ISO VG 320 CLP
AGMA 6EP
Table 4 Alternative oil types

ARAL Degol BMB 320
BP Energol GR-XP 320
Castrol Alpha SP 320
Chevron NL. Gear compounds EP 320
DEA Falcon CLP 320
ELF Reductelf SP320
Esso Spartan EP 320
Exxon Spartan EP 320
Fina Giran L320
Gulf EP lubric. HD 320
Mobil Mobilgear 632
Q8 Goya 320
Optimol Optigear 320
Shell Omala 320
Statoil LoadWay EP320
Sunoco Sunep 1060 ISO 320
Texaco Meropa 320
Total Carter EP 320
Tribol Tribol 1100 320
Wintershall Ersolan 320
The oil suppliers are responsible for the selection and the composition of their products.
They should confirm that there is no problem with sealings made of NBR. Do not mix
different products without agreement of the suppliers.

Preventive Maintenance
3 Preventive Maintenance
The following includes instructions for performing scheduled preventive maintenance on
the IRB 5400-02 manipulator. For a complete maintenance operation, also perform
maintenance for:
Control Cabinet - Ref.: ‘Unit Description’ manual, 3HNT 01023-1
Paint System - Ref.: ‘Unit Description - Paint’ manual, 3HNT 01337-1
WARNING!
No maintenance work must be performed before the ’Safety Guidelines’ on page 7
and Safety Precautions below have been read.
3.1 Safety Precautions
WARNING!
No work must be performed on the system before the Safety Manual, has been
studied carefully. In addition, following points must be observed:
Be sure that the electrical mains switch is ‘off’ and properly marked or locked
before performing any work outlined in the following.
Use only items listed in the Spare Parts Catalogue to avoid possible damage to the
robot or degradation of its performance or affect the ex-certification of the robot.
The maintenance activities described must only be performed by skilled personnel
with proper training.
Risks associated with volatile liquids have not been considered in the following.
Refer to instructions supplied with paints, solvents, etc., and information in Safety
Manual for advice.
Before starting to clean the spraying installation or before carrying out any other
work in the spray area, the high voltage supply system must be switched ‘off’,
protected against re-energizing, and ventilation system must be switched ‘on’.
It is extremely important that only electrically conductive containers are allowed to
be used for the cleaning liquid and they must be grounded.
Cleaning liquid may only be used if the flash point is at least 5K higher than the
ambient temperature.

3.2 General
General Considerations
The prime objective of any preventive maintenance program is to ensure maximum
system availability. Each scheduled and properly performed preventive maintenance
activity should assist in realizing this objective. Preventive maintenance that does not
reduce system downtime is unnecessary and costly.
The robot and paint system is designed to be able to work under very demanding
conditions with a minimum of maintenance. Nevertheless, certain routine checks and
preventative maintenance must be carried out at given periodical intervals.
When performing routine maintenance or repair work, a number of precautions must be
kept in mind to avoid introducing additional errors into the system.
• Do not perform more than recommended preventive maintenance on equipment
which is working satisfactorily.
• Wipe all surfaces clean before starting maintenance procedures.
• To avoid unnecessary contamination by dust etc., always clean outside of control unit
and manipulator before opening doors and covers.
How to Perform the Maintenance Activities

To perform the required maintenance operations, refer to the maintenance chart for a list
of the maintenance activities, recommended time intervals and reference to where
accomplishment instructions can be found.
Note that the intervals described are recommended intervals. The intervals needed for
your installation may vary, depending on paint type used, number of working hours etc.
The maintenance routines in this document must be seen in relation to the plant’s own
maintenance routines for the paint equipment.

3.3 Maintenance Chart
Table 5 Preventive maintenance chart
5
6
No. Activity and reference Interval

1 ’General Maintenance’ on page 22 Daily *1
2 ’Lubricate Balancing Transmission Bearings’ on page 24 3,000 hours *2
3 ’Lubricate Balancing Spring Rods’ on page 25 3,000 hours *2
4 ’Lubricate Hollow Wrist’ on page 23 3,000 hours
5 ’Check Oil Level in Gear Boxes’ on page 26 5 years
6 ’Measuring System Battery - Non-Ex / Old Style’ on page 27 3 years *3
*1 Interval strongly dependent on environmental conditions.

*2 For robots older than 2000, this interval is 500 hours due to a different type of bearings on these robots.
*3 Depending on robot operating hours and temperature.

3.4 General Maintenance

Following points should be checked / attended to as often as required.
Cleaning the Manipulator

The manipulator base and arm assembly should be cleaned regularly. Solvents may be
used but with care. Strong solvents such as acetone etc. should be avoided. High pressure
cleaning devices may be used, but spraying directly on the manipulator should be
avoided. If the manipulator is protected by canvas or plastic etc., replace as required.
Clean Hollow Wrist

The hollow wrist must be cleaned as often as required, if necessary every day, to avoid
accumulation of dirt and dust particles. Use a lint-free cloth for cleaning. When the wrist
is clean, a small amount of Vaseline or similar should be added to the wrist surfaces. This
will simplify the next cleaning.
Check Regularly
• For oil leaks. If a major oil leak is discovered, call for service personnel.
• For excessive play in gears. If this develops, call for service assistance.
• That cables between control cabinet, purge unit and manipulator are not damaged.
Check Floor Attachment Screws

Fastening screws and clamps which fasten the manipulator or rail system in position to
the foundation must be kept clean for corrosive fluids such as water, basic solutions and
acid solutions. This to avoid corrosion of security parts. If the corrosion protection such
as zinc coat or paint have been damaged, parts must be cleaned and covered by anti-
corrosive paint.

3.5 Lubricate Hollow Wrist
Figure 3 Hollow wrist lubrication points
4 5 6 7 (On opposite side)

1 2 3
Screwdriver
8 9 10
= Seal lubrication
Seal
The hollow wrist is located on the front of the manipulator arm. This procedure provides
necessary instructions for lubricating the wrist.
Required Tools and Items

– OMEGA 77 grease
– Grease pump
– Small screw driver
IMPORTANT. Read ’Safety Precautions’ on page 19 before continuing.
1. Using a small screw driver, open seals as shown in the lower right in figure 3. Add a
little lubricant (0.5g) of specified type at 5-6 different positions around the seal.
2. Repeat operation for all 4 seals at the side marked with arrows in the illustration.
3. Fill a grease pump with grease of specified type.
Caution: When lubricating the wrist, a few 'drops' of lubricant (1g) is sufficient at
each grease nipple. Do not insert a larger portion of lubricant, as this may damage
the wrist seals and internal sleeve.
4. Lubricate grease nipples 1 - 10, one by one, by pressing a very small portion (1g) of
grease into each nipple.
5. Repeat lubrication after turning each of the axes 4,5,6 by 90°, 180° and 270°.

3.6 Lubricate Balancing Transmission Bearings
Figure 4 Balancing spring link system, base right side view

The illustration shows the transmission for axis 3, located on the right side of the base (rear view). The
transmission system for axis 2 on the opposite side is similar and has identical lubricating points.
= Lubrication points

– Omega 77 grease
– Grease pump
– 13 mm ring key
1. Remove cover to get access to the four bearings for the balancing transmission.
2. Fill a grease pump with grease of specified type.
3. Press a small portion of grease into each of the 4 bearings.
4. Check that seal ring is undamaged and properly positioned. Re-install cover.
5. Repeat operation for bearings for axis 2.

3.7 Lubricate Balancing Spring Rods
Figure 5 Balancing spring rod, base right side view
= Lubrication points

– Omega 77 grease
– Hand tools
1. Move vertical arm (axis 2) to forward or backward position, and horizontal arm
(axis 3) down to expose balancing spring rods to be lubricated.
2. Remove spring cover for axis 2 on left side at the rear of the robot base.
3. Using a brush or similar, add a portion of grease of specified type to the balancing
spring rod.
4. Re-install cover.
5. Repeat operation for balancing spring rod (axis 3) on the right side.

3.8 Check Oil Level in Gear Boxes
Figure 6 Location of oil filling plugs
Filling plug Filling plug

Upper bevel gear Axis 4-6 gear box
(Check with arm in
front position)
Filling plug
Lower bevel gear
(Check with arm in
rear position)
Filling plug
Axis 1 gear box
Filling plug
Axis 3 gear box
(Axis 2 on opposite side)
The gear boxes are lubricated for life with oil which corresponds to 40 000 hours in
operation if the robot is operating in an environment temperature below 40°C.
To check oil level, open filling plugs and check that oil level is up to the filling hole. If
not, top up with specified oil type.
Note: Before removing the filling plug to check the oil level in the vertical arm bevel
gears, the arm must be moved to fully forward position to check the upper bevel gear,
and to fully backwards position to check the lower bevel gear.
For specification of oil type, specified oil level and filling instructions, see:
’Replace Oil for Axes 1, 2, 3’ on page 148
’Replace Oil in Bevel Gears’ on page 149
’Replace Oil for Axes 4-6 - Hollow Wrist Arm’ on page 151

3.9 Measuring System Battery - Non-Ex / Old Style

This procedure applies only for non-ex robots and old style robots. For later versions of
the ex-robot, the battery is located in the control cabinet and replacement instructions are
available in the ‘Unit Description S4P+’ manual.
Figure 7 Location of battery

1
3
4

– Rechargeable Nickel-Cadmium (Ni-Cd) battery
– Hand tools
1. Place the robot into calibration position (markings on the axes).
2. Remove cover (7/1) to get access to the backup battery (7/2).
3. Disconnect the battery connector (7/5).
4. Remove screw (7/3) and battery clamp (7/4). Remove old battery.
5. Install new battery using same clamp. Position the new battery in the same way as
the removed battery. Secure clamp.
6. Connect battery connector(s).
7. Re-install cover.
8. Perform calibration.
9. Charge battery. The battery takes 36 hours to recharge; the mains supply must be
switched on during this time.
WARNING!
Only batteries specified by ABB Robotics must be used. Old batteries must always
be handled as hazardous waste. A battery may explode if damaged or disposed off
in fire. Do not short-circuit battery
For general information on measuring system battery, see ‘Unit Description S4P+’
manual, section ‘Power Supply System’. (For S4P, see ‘Maintenance’ manual
3HNT 00093-1).


Base Unit Guidelines
4 Base Unit Guidelines

Following procedures provide information for replacing components on the base unit for
the IRB 5400-0x robots.

4.1 Removal of Motor for Axes 1, 2, 3
LOCATION
The motors for axes 1, 2 and 3 are located in the base unit as shown in the figure below.
Figure 8 Base unit, right side view
Motor 3 (Motor 2 Motor 3 cover (Motor 2

on opposite side) cover on opposite side)
Motor 1 cover
Motor 1
REFERENCES
’Releasing Axis Brakes’ on page 11
figure 104
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 motor removal (right side motor - rear
view). Axis 2 motor removal (left side motor - rear view) and axis 1 motor removal
procedures are identical unless specifically noted.
WARNING!
No repair work must be performed on the robot before the safety regulations in
’Safety Guidelines’ on page 7 have been read and understood.
1. Prepare operation.
a. Release axis brakes. Ref. ’Releasing Axis Brakes’ on page 11.
b. Move robot arm to a suitable position. Support robot arm using a strap and
lifting device or place the arm on a table or similar to prevent it from dropping
when removing motor. This is especially important when additional weight is
mounted on the robot arm.
c. Activate brakes.
d. Turn the electrical disconnect switch ‘off’ and lock switch in ‘off’ position.

WARNING!
Be sure that electrical switch is ‘off’ and locked in ‘off’ position before continuing.
e. Remove oil from gearbox for axis 3 (alternatively axis 2) by placing a tray under
drain plug (104/16) and removing the plug. The required amount (approx.
2 liters) will then be drained from the gearbox. (For axis 1, it is not necessary to
remove oil from gearbox).
Note. For robots older than winter-02 this drain plug does not exist. The motor
may in this case be removed without first draining the oil in the gearbox. In this
case approximately 1 liter of oil will run out when loosening the motor
attachment screws. The oil may be collected by placing a piece of cardboard etc.
under the motor and let the oil flow into a tray or similar. Alternatively, the
required amount of oil may be drained as described in ’Replace Oil for Axes 1,
2, 3’ on page 148.
f. Remove right side motor cover (104/3) to get access to motor to be replaced.
(axis 1: remove base top cover (104/4), axis 2: remove left side motor cover
(104/10).
2. Disconnect electrical connections.
a. Remove clamps (9/3) fastening cables to motor.
b. Disconnect motor connector (9/4).
c. Disconnect measuring system connector (9/2).
WARNING!
Arm must be supported before continuing.
3. Remove motor.
a. Note position of motor before removing it.
For axis 1, remove 2 e.a. attachment screws for control board and move board
aside to enable removal of motor.

Figure 9 Motor for axis 3, removal
1
1
4
3
3
b. Remove 4 e.a. attachment screws (9/1). Retain screws for use with new motor.
c. Remove motor.
WARNING!
Axis brake has no function when a motor is removed (arm is free).

4.2 Installation of Motor for Axes 1, 2, 3
LOCATION
The motors for axes 1, 2 and 3 are located in the base unit as shown in the figure below.
Motor 3 (Motor 2 Motor 3 cover (Motor 2

on opposite side) cover on opposite side)
Motor 1 cover
Motor 1
REFERENCES
TOOLS AND ITEMS

Hand tools
Main axes rotor rotating tool
PROCEDURE
Note: The following guidelines are for axis 3 motor installation (right side motor - rear
view). Axis 2 motor installation (left side motor - rear view) and axis 1 motor installation
procedures are identical unless specifically noted.
WARNING!
WARNING!
a. Clean mounting surface on motor flange and base using a lint-free cloth.
b. Check that motor flange and mounting surface on base are not scratched or
damaged.

c. Make sure that the o-ring is properly positioned in the groove. Add 4 spots of
grease pitched 90° in the groove to keep o-ring in position.
Figure 11 Motor for axis 3, installation
2. Install motor.
a. Place new motor in correct position in base unit.
b. Install mounting screws (11/1) and tighten with torque 2 Nm.
3. Align motor.
a. Insert screw of rotor rotating tool on rear of motor shaft (11/2). Rotate tool until
it stops. Tighten lightly.
b. Release axis brakes for motor. Ref. ’Releasing Axis Brakes’ on page 11.
c. Place a large screwdriver (11/3) or other suitable tool between the motor flange
and the base unit wall.
d. Bend carefully using the screwdriver while rotating rotor until play is at a
minimum.
e. Use a combination of turning the rotor using the tool and move the robot
horizontal arm up / down by hand (axis 2: Move vertical arm forwards /
backwards, axis 1: Move arm sideways) to find the position where the play
between the gear of the motor and gearbox is the smallest.
f. Bend carefully using the screwdriver while rotating rotor until play is next to
nothing.
g. Cross-tighten motor screws.
h. Rotate rotor and move arm to feel that rotation is not too tight or loose over the
full area of the motion of the robot arm.
i. Activate axis brakes.
j. Remove rotor rotating tool.

k. For axis 1 motor, put system control board back in place and secure attachment
screws.
4. Refill oil.
a. Re-install drain plug (104/16) and remove filling plug (104/15) for axis 3
(alternatively axis 2). Refill oil in gearbox and re-install filling plug.(This point
does not apply for axis 1 as oil does not need to be removed to replace motor 1).
Note. For robots older than winter-02, refill oil as described in ’Replace Oil for
Axes 1, 2, 3’ on page 148.
5. Conclude operation.
a. Insert connectors for motor and measuring system.
b. Clamp cables to motor.
c. Install cover.
d. Calibrate the robot as described in ’Calibration Procedure’ on page 173.

4.3 Disengage Balancing Spring

This procedure describes how to transfer the balancing spring force from the robot arm
to the spring unit itself. The procedure is required as part of several procedures in this
manual.
LOCATION
The balancing springs are located, one on each side, in the lower rear section of the base
unit as shown in the figure below.
Axis 3 balancing spring

Axis 2 balancing Axis 3 balancing

spring cover spring cover
REFERENCES
figure 104
figure 105
TOOLS AND ITEMS

Guiding bolt tool
Hand tools
PROCEDURE
Note: Always use the arm as lever arm for compressing spring. Adjusting the screws
will then be possible with very low forces.
Note: The following guidelines are for axis 3 spring (right side spring - rear view).
Axis 2 spring (left side spring - rear view) guidelines are identical unless specifically
noted.
WARNING!
a. Turn the electrical disconnect switch ‘off’ and lock switch in ‘off’ position.

WARNING!
b. Remove right side cover, (104/8) to get access to spring adjusting screw. (axis 2:
remove left side cover (104/9).
c. Remove right hand side rear spring cover (104/5) to get access to guiding bolt.
(axis 2: remove left hand side rear cover (104/11).
2. Compress spring.
a. Remove guide bolt lock screw (105/8) at front of spring adjustment screw
(105/7). Retain screw for re-installation. See also figure 13, right illustration.
b. Suspend robot arm using lifting device and strap etc.
WARNING!
Be sure that robot arm is suspended before continuing.
c. Release axis brakes. Ref. ’Releasing Axis Brakes’ on page 11.
d. Move horizontal arm down (axis 2: vertical arm forwards or backwards) to
compress spring.
e. Activate axis brakes.
Figure 13 Secure spring, right side view
3. Disengage spring.
a. Install guiding bolt tool (105/3) on guiding bolt (105/2). See also figure 13, left
illustration.
b. Attach a pipe wrench to end of guiding bolt tool.
c. Tighten guiding bolt 10 - 12 revolutions or until it stops by rotating clockwise.
d. Be sure that arm is suspended and release axis brake for axis 3 (or axis 2). Ref.
’Releasing Axis Brakes’ on page 11.

e. Lift horizontal arm (axis 2: move vertical arm towards vertical position) until
you can feel that spring is no longer applying force to the arm (spring is free).
f. If force is still applied to the arm, rotate spring adjustment screw (105/7) counter
clockwise to prepare for increasing spring tension. (Adjustment should be done
when horizontal arm is lifted all the way up (vertical arm in vertical position)).
Then move arm to compress spring and tighten guiding bolt a few revolutions.
Repeat above step until you can feel that spring force is no longer applied to the
arm.
g. Activate axis brakes. Suspend or support robot arm as required.
h. Remove guiding bolt tool.
i. Grab with one hand at rear end of spring and one hand at the front end. If spring
is free you should be able to move it back and forth.
WARNING!
The robot arm is not balanced when the balancing is disengaged. To prevent
hazardous situations mark brake release function properly to prevent accidental
releasing of the axis brakes. Additionally the robot arm needs to be suspended or
supported, because the axis brakes are not always able to prevent the arm from
sagging, especially when additional equipment is mounted on the arm.

4.4 Engage Balancing Spring

This procedure describes how to transfer the balancing spring force from the spring back
to the robot arm after repair work has been performed on the robot.
LOCATION

Axis 2 balancing Axis 3 balancing

spring cover spring cover
REFERENCES
figure 105
TOOLS AND ITEMS

Guiding bolt tool
Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 spring (right side spring - rear view).
Axis 2 spring (left side spring) guidelines are identical unless specifically noted.
WARNING!
WARNING!

WARNING!
Releasing axis brakes when spring is disengaged will cause the robot arm to drop
rapidly if arm is not suspended.
b. Make sure that robot arm is properly supported and release axis brake for axis 3
(axis 2: release brake for axis 2). Ref. ’Releasing Axis Brakes’ on page 11.
c. Move horizontal arm all the way down (axis 2: move vertical arm all the way
forwards or backward) to compress spring.
d. Activate brakes.
2. Engage spring.
a. Unscrew guiding bolt (105/2) by rotating counter clockwise using guiding bolt
tool (105/3) and pipe wrench. Rotate the same number of turns as the bolt was
tightened with when spring tension was transferred from robot arm to spring.
(10 - 12 turns).
CAUTION: Do not unscrew the guiding bolt more than specified. If the bolt is
fully removed from its threads, it can be hard to re-engage threads.
b. Insert guiding bolt lock screw (105/8) at front of spring adjustment screw
(105/7). Tighten guiding bolt lock screw.
Important: When the guiding bolt lock screw is secured, a gap (105/16) of
2 mm ± 1 mm must be present between the head of the guide bolt lock screw
(105/8) and the front of the adjustment screw (105/7). If this is not the case,
loosen guiding bolt lock screw, adjust guiding bolt and try again.
c. Tighten guiding bolt (105/2) at the back with a torque of 20 Nm.
a. Install side cover.
b. Install spring end cover.

4.5 Removal of Balancing Spring
LOCATION

REFERENCES
’Disengage Balancing Spring’ on page 36
figure 105
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 spring removal (right side spring - rear
view). Axis 2 spring (left side spring - rear view) removal procedure is identical unless
specifically noted.
WARNING!
WARNING!
b. Transfer balancing spring force from robot arm to spring as described in
procedure ’Disengage Balancing Spring’ on page 36.

WARNING!
The balancing spring removed from the robot, and the replacement spring are
under a considerable tension and form a potential hazard. Rough handling,
dropping etc. of the spring must be avoided.
2. Remove spring.
a. Install 2 e.a. M6x20 mm screws (105/17) in right hand side spring unit nut
(105/1) (axis 2: left hand spring unit nut).
Note. You may use the cover attachment screws for this purpose if above screws
are not available. If you use the cover attachment screws, be extra careful not to
damage the screws or screw threads when performing the next step.
b. Place a rod (105/18) between the screws and use it as lever arm.
c. Remove ring by rotating counter clockwise. Retain ring for later re-installation.
d. Pull spring out.
WARNING!
Do not try to disassemble spring unit. The complete spring assembly must be
handled as one unit.

4.6 Installation of Balancing Spring
LOCATION

REFERENCES
’Engage Balancing Spring’ on page 39
’Adjusting Balancing Spring Tension’ on page 45
figure 105
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 spring installation (right side spring - rear
view). Axis 2 spring (left side spring) installation procedure is identical unless
specifically noted.
WARNING!
WARNING!
2. Insert new spring.
a. Insert spring. Guide adjustment screw (105/7) into wrist pin (105/14) to engage
front of spring with balancing transmission. Rotate wrist pin (105/14) as
necessary to engage adjustment screw.

Note: Make sure that grease nipple (105/6) on wrist pin is facing upwards.
b. Install spring unit nut (105/1) and tighten.
c. Remove 2 screws (105/17) used for tightening spring unit nut.
a. Transfer spring tension back to robot arm as described in procedure ’Engage
Balancing Spring’ on page 39.
b. Check balancing of robot arm. If balancing is not as required, adjust spring
tension as described in procedure ’Adjusting Balancing Spring Tension’ on page
45.
c. Install covers.

4.7 Adjusting Balancing Spring Tension
LOCATION
Figure 17 Adjust spring tension, robot base right side
REFERENCES
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 spring adjustment (right side spring - rear
view). Axis 2 spring (left side spring) adjustment procedure is identical unless
specifically noted.
WARNING!
1. Transfer spring tension from robot arm to spring as described in procedure
’Disengage Balancing Spring’ on page 36.
2. Rotate spring adjustment screw as shown in figure 17. Rotate screw clockwise to
reduce spring tension or counter clockwise to increase spring tension.
3. Transfer spring tension back to robot arm as described in procedure ’Engage
Balancing Spring’ on page 39.
4. Check that spring tension is as required. If not, repeat procedure from step 1.

4.8 Removal of Bearings in Connection Rod
LOCATION
The connection rods are located, one on each side, in the front section of the base unit as
shown in the figure below.
Upper bearing
Axis 3 balancing spring connection rod

(Axis 2 spring on opposite side)
Lower bearing
REFERENCES
figure 104
figure 105
TOOLS AND ITEMS

1 or 2 small pullers
Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 connection rod (right side - rear view).
The removal procedure for axis 2 connection rod is identical unless specifically noted.
WARNING!
WARNING!
b. Release spring tension for axis 3 (104/5) (Axis 2: Release spring tension for axis
2 (104/11)) as described in procedure ’Disengage Balancing Spring’ on page 36.
c. Mark connection rod to ensure correct positioning during re-installation.

d. Suspend robot arm using lifting device and straps etc.
WARNING!
Removing balancing spring connection rod must under no circumstances be
attempted if the balancing springs has not been disengaged.
2. Remove balancing spring connection rod.
Axis 2: References in the following steps refer to components on the opposite side
of the robot base.
a. Remove retaining ring (105/4) at upper end.
b. Remove retaining ring (105/10) at lover end.
c. Remove steel plate and plastic cover (105/5) for upper bearing.
d. Remove steel plate and plastic cover (105/11) for lower bearing.
WARNING!
If the robot arm is not properly suspended, the arm will drop rapidly when
performing next step.
e. Use pullers and pull off connection rod (105/9). If you only have one puller
available, you must alternate between pulling a bit at the top and a bit at the
bottom.
3. Remove bearing(s).
a. Remove bearing at one or both ends as required.

4.9 Installation of Bearings in Connection Rod
LOCATION
The connection rods are located, one on each side, in the front section of the base unit as
Upper bearing
Axis 3 balancing spring connection rod

(Axis 2 spring on opposite side)
Lower bearing
REFERENCES
figure 105
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 connection rod (right side - rear view).
The installation procedure for axis 2 connection rod is identical unless specifically noted.
WARNING!
WARNING!
2. Install new bearing(s).
a. Install new bearing or bearings in connection rod. Use a plastic hammer to
knock bearing(s) into position in the bearing housing.
b. Place the connection rod across the upper and lower attachment shafts.
c. Using a plastic hammer, carefully knock connection rod into position, knocking
alternately on upper and lower bearing.

3. Install bearing covers.

of the robot base.
a. Install plastic cover and steel plate (105/5) for upper bearing.
b. Install plastic cover and steel plate (105/11) for lower bearing.
c. Install retaining ring (105/4) at upper end.
d. Install retaining ring (105/10) on lower shaft.
a. Re-apply spring tension as described in procedure ’Engage Balancing Spring’ on
page 39.
b. Remove arm suspension.
c. Install covers.

4.10 Removal of Balancing System Crank Arm
LOCATION
The balancing system crank arms are located, one on each side, in the lower front section
of the base unit as shown in the figure below.
Balancing system crank arm
REFERENCES
’Removal of Bearings in Connection Rod’ on page 46
figure 104
figure 105
TOOLS AND ITEMS

Slide hammer puller (Removal can be performed without this puller)
Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 crank arm removal (right side - rear view).
The removal procedure for axis 2 crank arm is identical unless specifically noted.
WARNING!
WARNING!

WARNING!
Removing of the crank arm must under no circumstances be attempted without
first disengaging the balancing spring.
c. Remove connection rod (105/9) as described in procedure ’Removal of Bearings
in Connection Rod’ on page 46.
2. Remove crank arm shaft.
Note: The crank arm shaft (105/13) is equipped with a M10 hole in the centre. This
enables you to use a slide hammer puller for extracting the shaft instead of knocking
it out as described below.
of the robot base.
a. Remove retaining ring (105/15) for crank arm shaft.
b. Using a plastic hammer, knock the crank arm shaft (105/13) in 5 - 10 mm to
press out cap at back.
c. Using a hammer and a dowel, knock out crank arm shaft from the back.
d. When shaft is free, pull out by hand.
3. Remove crank arm.
a. Bend crank arm (105/12) down at front to free wrist pin (105/14) from spring
adjustment screw (105/7).
b. Remove crank arm.

4.11 Installation of Balancing System Crank Arm
LOCATION
The balancing system crank arms are located, one on each side, in the lower front section
of the base unit as shown in the figure below.
Balancing system crank arm
REFERENCES
’Installation of Bearings in Connection Rod’ on page 48
figure 105
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 crank arm installation (right side - rear
view). The installation procedure for axis 2 crank arm is identical unless specifically
noted.
WARNING!
WARNING!
2. Install new crank arm.
of the robot base.
a. If retaining ring (105/15) was removed, re-install ring.

b. Place crank arm (105/12) in position.

c. Insert shaft (105/13) and knock into position using a plastic hammer.
d. Re-install cap at back as required.
a. Install connection rod (105/9) as described in procedure ’Installation of Bearings
b. Re-apply spring tension as described in procedure ’Engage Balancing Spring’ on
page 39.
c. Install covers.

4.12 Removal of Balancing System Lever Arm
LOCATION
The balancing system lever arms are located, one on each side, in the front section of the
base unit as shown in the figure below.
Balancing system lever arm
REFERENCES
figure 104
figure 105
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 lever arm removal (right side). The
removal procedure for axis 2 lever arm is identical unless specifically noted.
WARNING!
WARNING!

WARNING!
Removing of the lever arm must under no circumstances be attempted without first
disengaging the balancing spring.
c. Remove connection rod (105/9), including bearing at lever arm, as described in
procedure ’Removal of Bearings in Connection Rod’ on page 46.
2. Remove lever arm.
of the robot base.
a. Note position of lever arm (105/19) to ensure correct installation of new lever
arm.
b. Remove 8 attachments screws (105/20) securing lever arm to axis shaft. Retain
screws for use with new lever arm.
c. Remove lever arm. Discard old lever arm.

4.13 Installation of Balancing System Lever Arm
LOCATION
The balancing system lever arms are located, one on each side, in the front section of the
base unit as shown in the figure below.
Balancing system lever arm
REFERENCES
figure 105
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 lever arm installation (right side). The
installation procedure for axis 2 lever arm is identical unless specifically noted.
WARNING!
WARNING!
2. Install new lever arm.
of the robot base.
a. Clean mounting surface.
b. Place new lever arm (105/19) in correct position.

c. Install attachment screws (105/20). Cross-tighten screws.

a. Install connection rod (105/9), including bearing at lever arm, as described in
procedure ’Installation of Bearings in Connection Rod’ on page 48.
b. Re-apply spring tension as described in procedure ’Engage Balancing Spring’ on
page 39.
c. Install cover.

4.14 Removal of Axis 1 Main Shaft Gearbox Seal

The removal procedure may not be fully accurate, as the robot can be equipped with
different cable versions.
LOCATION
The axis 1 main shaft gearbox seal is located at the bottom of the base unit as shown in
the figure below.
Figure 24 Base unit, bottom view
Seal
REFERENCES
figure 104
TOOLS AND ITEMS

Vise grip plier
Hand tools
PROCEDURE
WARNING!
a. Place the robot in a stable position. This position is depending on the weight of
additional equipment mounted on the robot arms.
b. Turn the electrical disconnect switch ‘off’ and lock switch in ‘off’ position.
WARNING!

c. Remove oil from axis 1 gearbox, as described in ’Replace Oil for Axes 1, 2, 3’
on page 148.
d. Prepare a suitable container to collect the oil that will slowly drip out of the
gearbox when the seal has been removed.
e. Attach lifting straps to robot and tension lifting straps. Check that straps are
properly secured. For lifting instructions, see the ‘Installation and
Commissioning manual’.
f. Seal the ventilation plugs for axis 1, 2 and 3.
g. Remove cover from foot unit (104/12) / raiser unit / trolley foot unit.
h. Remove center cover from base unit.
2. Remove robot cables.
Note: For more detailed information, see ’Removal of Cables Foot Unit - Base Unit’
on page 154.
a. Disconnect control cables from termination bracket in foot unit.
b. Loosen hose nut in foot unit by hand and lift hose out of the termination bracket.
c. The 2 nuts/screws securing the termination bracket are now visible, remove
these 2 nuts/screws.
d. Disconnect robot cable connectors from termination bracket.
e. Loosen hose bracket in base top center compartment.
f. Pull complete cable/hose harness out of foot unit.
3. Lift robot.
Note: Instructions only applicable for robot equipped with standard foot unit. When
robot is not equipped with a standard foot unit, continue with step 4.
a. If required, remove control cables out of foot unit.
b. Remove screws, securing the robot foot unit to foundation. Retain screws for
reinstallation.
WARNING!
Do not walk under hanging load.
c. Lift robot vertically. Place the robot in a convenient position and support the foot
unit in such a way that following procedure can be performed in an easy and
secure way.
4. Remove foot unit from base unit.
a. Remove bottom cover from standard foot unit / raiser foot.
WARNING!
Support standard foot unit! The standard foot unit weights approx. 150kg.

b. Remove screws connecting foot unit to robot base unit.
WARNING!
c. Lift robot vertically.
d. Place the robot in a convenient position, e.g. lay it down on front or rear side,
and support the robot base unit in such a way that following procedure can be
performed in an easy and secure way.
5. Remove gearbox seal.
a. Use a center punch and a hammer to make 2 small holes in the gearbox seal
(figure 24).
b. Insert 2 wood screws in the holes.
c. Pull out the gearbox seal using a vise grip plier. Discard old gearbox seal.
d. Collect the oil dripping out of the gearbox.

4.15 Installation of Axis 1 Main Shaft Gearbox Seal

The installation procedure may not be fully accurate, as the robot can be equipped with
LOCATION
The axis 1 main shaft gearbox seal shall be located at the bottom of the base unit as
Figure 25 Base unit, bottom view
Seal
REFERENCES
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
a. Clean the surface of the axis with a lint-free cloth.
2. Install new gearbox seal.
a. Check the surface of the axis for scratches and wearing. If needed, use a rubbing
brick to remove damages that may have caused the leakage.
b. Add grease on inside of the new gearbox seal.
c. Add Loctite 2701 on outside of new gearbox seal.

d. Install the new gearbox seal. Use a hammer and a suitable part of wood or
similar to knock the new seal carefully in position.
Note: The seal needs to be pushed equally on all sides. Never hammer directly
on the seal, as this may result in leakage.
3. Install foot unit.
a. Apply Loctite 574 to flange on foot unit.
WARNING!
b. Lift robot over foot unit and lower the robot into position on the foot unit.
c. Install screws to secure the robot to the foot unit. Tighten screws using standard
torque.
d. Clean foot unit bottom cover and bottom of foot unit. Add Loctite 5221 on
flange to provide a flexible sealing between the cover and the foot unit. Install
bottom cover.
4. Install cables.
Note: For more detailed information, see ’Installation of Cables Foot Unit - Base
Unit’ on page 156.
a. Route the cable ends equipped with A1 receptacles from base unit top center
compartment into foot unit.
b. Align cables, avoid all crossing and twisting.
c. Install hose bracket in base unit top center compartment.
d. Install A1 receptacles on termination bracket in foot unit. Avoid any twisting in
the cables leading to the base unit. Ensure that cables in foot unit are aligned and
that the hose is pointing straight vertical.
e. Install termination bracket in foot unit.
WARNING!
a. Lift robot with installed standard foot unit and place the robot on foundation.
Install screws, securing robot foot unit to foundation.
b. Remove Lifting straps.
c. Remove sealings from ventilation plugs.
d. Install control cables in foot unit.
e. Fill axis 1 gearbox with oil, as described in ’Replace Oil for Axes 1, 2, 3’ on
page 148.
f. Install all covers.

4.16 Removal of Axis 2 and 3 Main Shaft Gearbox Seal
LOCATION
The axis 2 and 3 main shaft gearbox seals are located, one on each side, in the front
section of the base unit as shown in the figure below.
Seal
REFERENCES
’Removal of Balancing System Lever Arm’ on page 54
figure 104
figure 105
TOOLS AND ITEMS

Vise grip plier
Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 gearbox seal removal (right side - rear
view). The removal procedure for axis 2 gearbox seal is identical unless specifically
noted.
WARNING!
WARNING!
b. Remove right side base unit cover (104/8). (Axis 2: Remove left side base unit
cover).

c. Release spring tension for axis 3 (104/5) (Axis 2: Release spring tension for
axis 2 (104/11)) as described in procedure ’Disengage Balancing Spring’ on
page 36.
WARNING!
Removing the connection rod must under no circumstances be attempted without
first disengaging the balancing spring.
d. Remove connection rod (105/9), including bearing at lever arm, as described in
procedure ’Removal of Bearings in Connection Rod’ on page 46.
e. Remove lever arm (105/19), as described in procedure ’Removal of Balancing
System Lever Arm’ on page 54.
f. Prepare a suitable container to collect the oil that will slowly drip out of the
gearbox when the seal has been removed.
2. Remove gearbox seal.
of the robot base.
a. Use a center punch and a hammer to make 2 small holes in the gearbox seal
(105/21).
b. Insert 2 wood screws in the holes.
c. Pull out the gearbox seal using a vise grip plier. Discard old gearbox seal.
d. Collect the oil dripping out of the gearbox.

4.17 Installation of Axis 2 and 3 Main Shaft Gearbox Seal
LOCATION
The axis 2 and 3 main shaft gearbox seals are located, one on each side, in the front
section of the base unit as shown in the figure below.
Seal
REFERENCES
’Installation of Balancing System Lever Arm’ on page 56
figure 105
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for axis 3 gearbox seal installation (right side - rear
view). The installation procedure for axis 2 gearbox seal is identical unless specifically
noted.
WARNING!
WARNING!
a. Clean the surface of the axis with a lint-free cloth.
2. Install new gearbox seal.
of the robot base.

a. Check the surface of the axis for scratches and wearing. If needed, use a rubbing
brick to remove damages that may have caused the leakage.
b. Grease the new gearbox seal.
c. Install the new gearbox seal. Use a hammer and a suitable part of wood or
similar to knock the new seal carefully in position.
Note: The seal needs to be pushed equally on all sides. Never hammer directly
on the seal, as this may result in leakage.
a. Install lever arm (105/19), as described in procedure ’Installation of Balancing
System Lever Arm’ on page 56.
b. Install connection rod (105/9), including bearing at lever arm, as described in
procedure ’Installation of Bearings in Connection Rod’ on page 48.
c. Re-apply spring tension as described in procedure ’Engage Balancing Spring’ on
page 39.
d. Install cover.

Vertical Arm Guidelines
5 Vertical Arm Guidelines

Following procedures provide information for replacing components on the vertical arm
for the IRB 5400-0x robots.

5.1 Removal of Upper Bevel Gear Unit
LOCATION
The upper bevel gear is located at the top of the vertical arm as shown in the figure
below.
Figure 28 Upper bevel gear unit, robot right side view
Horizontal arm
Upper bevel gear
Vertical arm
REFERENCES
’Removal of Horizontal Arm’ on page 88
figure 104
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
b. Remove horizontal arm as described in procedure ’Removal of Horizontal Arm’
on page 88.

IMPORTANT: It is very important to note the exact position of the horizontal

arm before removing it. If this is not done, it can be difficult to install the new
bevel gear correctly. To note the position of the horizontal arm, place the arm to
point accurately at a fixed position or place it in exact horizontal position using a
leveller etc.
WARNING!
Brakes must under no circumstances be released as stated in the above procedure.
Releasing the brakes from now on can cause severe injury. Brakes must not be
released again until it is clearly stated in the installation procedure.
c. Remove vertical arm upper right side cover and rear cover (104/2).
2. Remove bevel gear unit.
a. Remove 4 screws (106/4) securing bevel gear unit to top of vertical arm. The
screws are accessed from the underside, inside the vertical arm. Retain screws
for re-installation.
b. Remove 4 screws (106/5) connecting bevel gear shaft to axis 3 drive shaft. If
applicable, first remove drive shaft protection bracket.
c. Lift off bevel gear unit from vertical arm.
Note. The unit includes guide pins and can be a little hard to get off. Use a
combination of lifting and carefully knocking using a plastic hammer during the
removal. You may also insert a screw driver into the holes (106/5) connecting
the axis 3 drive shaft to the bevel gear unit shaft and bend carefully.

5.2 Installation of Upper Bevel Gear Unit
LOCATION
The upper bevel gear is located at the top of the vertical arm as shown in the figure
below.
Figure 29 Upper bevel gear unit, robot right side view
Horizontal arm
Upper bevel gear
Vertical arm
REFERENCES
’Installation of Horizontal Arm’ on page 91
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
a. Clean mounting surface on bevel gear unit and vertical arm using a lint-free
cloth.
b. Check that bevel gear unit flange and mounting surface on arm are not
scratched.

2. Install bevel gear unit.

a. Add a small amount of grease to simmer-ring (106/9) on bevel gear unit shaft.
b. Position bevel gear unit guide pins in guide holes on top of vertical arm and
guide axis 3 drive shaft into position on bevel gear unit shaft.
c. Carefully knock bevel gear unit into position using a plastic hammer.
d. Install 4 screws (106/4) securing bevel gear unit to top of vertical arm.
3. Align bevel gear horizontal arm attachment and shaft.
The horizontal arm attachment on the bevel gear can be set in a number of different
positions which match the position of the horizontal arm noted before removal. Only
1 of these positions is however correct. If the holes of the horizontal arm attachment
does not match the holes in the bevel gear unit, find correct position by performing
following steps:
a. Place the horizontal arm in the exact same position as it had before removal.
b. Remove screws (106/7) from axis 3 drive shaft lower end attachment.
c. Rotate axis 3 drive shaft until holes at upper end matches the holes in the upper
bevel gear shaft. Install 2 of the 4 screws (106/5) and tighten.
d. Insert a suitable tool in the 2 free holes (106/5). Use this tool to rotate the axis 3
drive shaft.
e. Rotate the axis 3 drive shaft until the holes in the horizontal arm attachment
matches the holes in the bevel gear unit.
f. Check that the attachment holes at the lower end of the axis 3 shaft (106/7) and
the holes in the lower bevel gear shaft are fully open. If this is not the case, rotate
upper bevel gear until next pair of attachment holes for the horizontal arm are
aligned with the arm.
g. Repeat operation until holes are aligned and horizontal arm is correctly
positioned.
h. Install 4 screws (106/7) attaching axis 3 drive shaft to bevel gear unit shaft.
i. Remove tool and install 2 remaining screws (106/5) at upper end of drive shaft.
If applicable, install drive shaft protection bracket.
a. Install horizontal arm as described in procedure ’Installation of Horizontal Arm’
on page 91.
b. Calibrate the robot as described in ’Calibration Procedure’ on page 173.

5.3 Removal of Vertical Arm
LOCATION
The vertical arm is located on the robot as shown in the figure below.
Figure 30 Vertical arm
Horizontal arm
Vertical arm
REFERENCES
’Removal of Upper Bevel Gear Unit’ on page 68
figure 104
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
on page 88.

WARNING!
c. Remove upper bevel gear unit as described in procedure ’Removal of Upper
Bevel Gear Unit’ on page 68.
2. Remove axis 3 drive shaft.
a. Remove 4 screws (106/7) securing axis 3 drive shaft to lower bevel gear unit
shaft. Retain screws for re-installation.
b. Pull shaft out from vertical arm. Retain shaft for re-installation.
3. Remove electrical cable.
a. Follow cable for base unit from bottom of the vertical arm to their respective
connections. Disconnect connectors while marking them for correct re-
installation.
b. Remove 2 screws (106/13) securing electrical cable hose to vertical arm bottom
plate.
c. Pull cable out from vertical arm.
4. Remove vertical arm.
Figure 31 Vertical arm lower attachment
Front view Left side view (axis 2)
a. Before untightening any screws, the balancing spring for axis 2 must be released
as described in ’Disengage Balancing Spring’ on page 36.
WARNING!
Removing the crank arm must under no circumstances be attempted without first
disengaging the balancing spring.
b. Remove 4 screws (106/16) securing vertical arm to lower bevel gear. The screws
are accessed from the inside of the arm.

c. Note position of axis 2 balancing system lever arm (31/1) to enable correct re-
installation. Remove screws (31/2) securing balancing system lever arm to
vertical arm shaft.
d. Remove screws (31/3) securing vertical arm to vertical arm shaft.
e. Note the position of vertical arm to be able to install new arm in same position.
Remove vertical arm.
Note. The vertical arm ‘hangs’ on a flange on the vertical arm shaft (106/14). To
remove the vertical arm, use a combination of lifting and knocking on the left
side (rear view) of the arm to bend it over during the lifting.

5.4 Installation of Vertical Arm
LOCATION
The vertical arm is located on the robot as shown in the figure below.
Figure 32 Vertical arm
Horizontal arm
Vertical arm
REFERENCES
’Installation of Upper Bevel Gear Unit’ on page 70
figure 31
figure 104
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Install vertical arm.
a. Place vertical arm in correct position on the vertical arm drive shaft (106/14).

Note. Use a combination of tilting and lowering the arm to engage it properly on
the flange of the vertical arm drive shaft.
b. Install screws (31/3) and tighten.
c. Install axis 2 balancing system lever arm (31/1) in correct position. Install
screws (31/2) and tighten.
d. Re-apply spring tension for axis 2 as described in ’Engage Balancing Spring’ on
page 39.
3. Install axis 3 drive shaft.
a. Place axis 3 drive shaft (106/6) in position on lower bevel gear shaft (106/15).
b. Install attachment screws for drive shaft (106/7).
a. Install upper bevel gear unit as described in procedure ’Installation of Upper
b. Install horizontal arm as described in procedure ’Installation of Horizontal Arm’
on page 91.
c. Install all covers.

5.5 Removal of Axis 3 Drive Shaft
LOCATION
The axis 3 drive shaft is located in the vertical arm as shown in the figure below.
Figure 33 Location of axis 3 drive shaft, robot right side view
Horizontal arm
Upper bevel gear
Axis 3 drive shaft
Vertical arm
Lower bevel gear
REFERENCES
figure 104
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
on page 88.

WARNING!
c. Remove upper bevel gear unit as described in procedure ’Removal of Upper
2. Remove axis 3 drive shaft.
a. Remove 4 screws (106/7) securing axis 3 drive shaft to lower bevel gear unit
shaft. Retain screws for re-installation.
b. Pull shaft out from vertical arm.

5.6 Installation of Axis 3 Drive Shaft
LOCATION
The axis 3 drive shaft is located in the vertical arm as shown in the figure below.
Figure 34 Location of axis 3 drive shaft, robot right side view
Horizontal arm
Upper bevel gear
Axis 3 drive shaft
Vertical arm
Lower bevel gear
REFERENCES
figure 104
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Install axis 3 drive shaft.
a. Place axis 3 drive shaft (106/6) in position on lower bevel gear shaft (106/15).
b. Install attachment screws for drive shaft (106/7).

a. Install upper bevel gear unit as described in procedure ’Installation of Upper
b. Install horizontal arm as described in procedure ’Installation of Horizontal Arm’
on page 91.
c. Install all covers.

5.7 Removal of Lower Bevel Gear Unit
LOCATION
The lower bevel gear unit is located at the lower end of the vertical arm as shown in the
figure below.
Horizontal arm
Vertical arm
Lower bevel gear
Base unit
REFERENCES
’Removal of Vertical Arm’ on page 72
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
a. Remove oil from bevel gear unit (106/17). Refer to ’Replace Oil in Bevel Gears’
on page 149 for information.

WARNING!
c. Remove horizontal arm as described in procedure ’Removal of Horizontal Arm’
on page 88.
WARNING!
d. Remove upper bevel gear unit as described in procedure ’Removal of Upper
e. Remove vertical arm as described in procedure ’Removal of Vertical Arm’ on
page 72.

2. Remove bevel gear unit.
Figure 36 Lower bevel gear unit
a. Remove axis 3 connecting rod as described in procedure ’Removal of Bearings

b. Note position of lever arm (36/3) and remove screws (36/4) securing lever arm
to axis 3 shaft. Retain lever arm and screws for re-installation.
Note: For axis 3, bearing must be removed to get access to screws (36/4).
c. Remove 2 blind screws (36/2) to get access to screws securing gear unit to axis 3
shaft.
d. Remove screws securing gear unit to axis 3 shaft. The screws are accessed from
the outside of the bevel gear unit, through the holes where the blind plugs was
removed. 2 screws can be removed at the time. Retain screws for re-installation.
(The screws are similar to the screws for the upper bevel gear as shown in
(106/8)).
e. Rotate gear unit to get access to next 2 screws. Remove screws. Repeat this
operation until only 2 screws remains holding the gear unit to the shaft.
f. Rotate gear unit housing until last 2 screws are located opposite blind screw
holes. Mark position of gear unit hosing related to gear housing and pinion shaft
related to gear unit housing.
g. Remove the last 2 screws.
h. Remove gear unit.

5.8 Installation of Lower Bevel Gear Unit
LOCATION
The lower bevel gear unit is located at the lower end of the vertical arm as shown in the
figure below.
Horizontal arm
Vertical arm
Lower bevel gear
Base unit
REFERENCES
’Installation of Vertical Arm’ on page 75
figure 104
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!

2. Install lower bevel gear unit.

a. Remove 2 blind screws (36/2) from new gear unit to enable installation of
screws securing gear unit to axis 3 shaft.
b. Lift gear unit (36/5) into correct position and install screws securing gear unit to
axis 3 shaft. The screws are installed from the inside of the bevel gear unit,
through the holes where the blind screws (36/2) were removed. 2 screws can be
installed at the time. Tighten screws.
c. Place lever arm (36/3) in correct position and install screws (36/4) securing lever
arm to axis 3 shaft. Tighten screws.
d. Install connecting rod as described in procedure ’Installation of Bearings in
Connection Rod’ on page 48.
a. Install vertical arm as described in procedure ’Installation of Vertical Arm’ on
page 75.
b. Install upper bevel gear unit as described in procedure ’Installation of Upper
c. Install horizontal arm as described in procedure ’Installation of Horizontal Arm’
on page 91.
d. Install all covers.
e. Refill oil in bevel gear unit (106/2). Refer to ’Replace Oil in Bevel Gears’ on
page 149 for information.
f. Calibrate the robot as described in ’Calibration Procedure’ on page 173.


H10 Horizontal Arm Guidelines
6 H10 Horizontal Arm Guidelines

Following procedures provide information for replacing components on the hollow wrist
horizontal arm.

6.1 Removal of Horizontal Arm
LOCATION
The horizontal arm is located on top of the vertical arm as shown in the figure below.
Figure 38 Vertical- and horizontal arm, robot right side view
Upper bevel gear

Horizontal arm
Vertical arm side covers
Vertical arm rear cover Vertical arm
REFERENCES
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Disconnect cables and hoses.
a. Remove vertical arm rear cover. Remove side cover if necessary.
b. Follow cable for horizontal arm from top of the vertical arm to their respective
connections. Disconnect connectors while marking them for correct re-
installation.

c. Remove 2 screws (106/3) securing cable hose to vertical top.

d. Pull out cable unit.
e. Disconnect paint and air supply hoses as required.
3. Remove arm attachment to bevel gear.
a. Remove 2 blind screws (106/1) on outside of bevel gear unit.
b. Release brakes for axis 3.
c. Move arm to fully upper position. Position arm so that 2 attachment screws are
accessible through the holes where the blind plugs were removed.
d. Activate brakes.
e. Remove screws (106/8) securing horizontal arm end housing to bevel gear unit.
The screws are reached from the outside of the bevel gear unit. Retain screws for
re-installation.
f. Release brakes for axis 3 and move horizontal arm a little downwards to get
access to next 2 screws. Activate brakes and remove screws. Repeat this
operation until 8 screws have been removed (2 screws remain attaching the
horizontal arm to the bevel gear).
g. Release brakes for axis 3 for the last time.
h. Before untightening the last two screws, release spring tension for axis 3 as
described in ’Disengage Balancing Spring’ on page 36.
Note: If the repair work is limited to the horizontal arm itself, the
counterbalance spring for axis 3 may stay engaged.
i. Position remaining screws so they are accessible. Activate brakes.
j. Disable the axis brake release function and mark brake release function to
prevent releasing the brakes by accident.
WARNING!
Brakes must under no circumstances be released from this point on. Releasing the
brakes from now on can cause severe injury. Brakes must not be released again
until it is clearly stated in the installation procedure.
k. Suspend horizontal arm to prevent the arm from falling when removing arm
attachment.
CAUTION: The horizontal arm is heavy (approximately 65 kg). Make sure that
arm is properly suspended before removing attachment screws.
WARNING!
Do not continue unless arm is properly suspended.
l. Mark position of arm and remove the last 2 screws.
Note. The horizontal arm may stick very hard on the joint to the bevel gear
(aluminium against steel). Before removing the left side arm attachment, the

horizontal arm should be moved up/down to free the joint. Note that
considerable force may be required to free the joint.
4. Remove left side arm attachment.
a. Move the horizontal arm to a position where it hangs straight down.
b. Remove 4 screws (106/10) from clamp ring on left side of horizontal arm rear
housing.
c. Pull out clamp ring (106/11) by hand.
WARNING!
Do not continue unless arm is properly suspended. The arm will fall when the
bearing bolt is removed in the next step
d. Using a plastic hammer or hammer and dowel etc. carefully knock out bearing
bolt (106/12) from the outside and inwards until arm is free.
e. Remove horizontal arm assembly.

6.2 Installation of Horizontal Arm
LOCATION
Upper bevel gear

Horizontal arm
REFERENCES
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Attach horizontal arm to left side attachment.
a. Lift horizontal arm into position on bevel gear.
b. Place bearing bolt (106/12) into position.
c. Install clamp ring (106/11) and secure with 4 screws (106/10).
3. Secure horizontal arm to bevel gear.
a. Move horizontal arm to correct position in accordance with marking etc. made
during removal.

b. Install first 2 screws (106/8) securing horizontal arm rear housing to bevel gear
unit. The screws are installed from the outside of the bevel gear unit, through the
blind plug holes. Tighten screws. It is important that these screws are tightened
with correct torque, see ’Tightening Torques’ on page 16.
c. If balancing springs have been disengaged, re-apply spring tension for axis 3 as
described in ’Engage Balancing Spring’ on page 39.
IMPORTANT: After engaging axis 3 balancing spring, it is safe to release the
brakes.
d. Release brakes for axis 3. Move horizontal arm up/down to get access to the next
2 screws. Activate brakes.
e. Install screws and tighten as described above.
f. Repeat this operation for all screws.
g. Install blind screws (106/1) in bevel gear.
4. Connect cables and hoses.
a. Route electrical cable hose into hole on top of vertical arm. Install attachment
screws (106/3) and secure.
b. Lead electrical cables down into vertical arm and connect according to markings
made during removal.
c. Connect paint and air supply hoses as required.
a. Refill oil in bevel gear unit (106/2). Refer to ’Replace Oil in Bevel Gears’ on
b. Install vertical arm covers.
c. Calibrate the robot as described in ’Calibration Procedure’ on page 173.

6.3 Removal of Horizontal Arm Drive Unit

This procedure describes replacement of the horizontal arm drive unit. This means the
complete horizontal arm except for the rear housing.
LOCATION
The horizontal arm drive unit is located on the horizontal arm as shown in the figure
below.
Figure 40 Location of horizontal arm drive unit
Rear housing Horizontal arm drive unit
Rear housing cover
REFERENCES
figure 104
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
a. Release axis brakes. Move vertical arm to vertical position and horizontal arm to
horizontal position. Activate brakes.
WARNING!
c. Remove horizontal arm rear housing cover (104/1). The purge sensor is mounted
on the inside of the cover. (Some old version may have it installed inside the
horizontal arm).

2. Remove connections for horizontal arm.
Figure 41 Connections, horizontal arm rear view
4 5 6 7
Note: Before disconnecting any connectors, ground wires or cable straps, carefully
note position to ensure correct re-installation, see also figure 41.
a. Disconnect purge connector(41/1), pull off air hose (41/2) for purge sensor and
remove cover.
b. Disconnect ground connection (41/3).
c. Disconnect axis motor 4, 5, 6 connections:
Disconnect 3 connectors for measuring system:
Axis 4 (41/6), axis 5 (41/4) and axis 6 (41/7).
Disconnect connector (41/5) for motor power. (Some old versions may have a
power connector for each motor).
WARNING!
3. Remove horizontal arm drive unit.
a. Suspend horizontal arm drive unit (104/7) using a lifting strap etc.
CAUTION: The horizontal arm drive unit is heavy (approximately 30 kg).
Make sure that arm is properly supported before removing attachment screws.
b. Unscrew screws (104/6) securing horizontal arm drive unit to rear housing.
c. Remove horizontal arm drive unit from rear housing.

6.4 Installation of Horizontal Arm Drive Unit
LOCATION
below.
Figure 42 Location of horizontal arm drive unit
Rear housing cover
REFERENCES
figure 41
figure 104
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Install horizontal arm
a. Place horizontal arm into position on front of the rear housing.
b. Install screws (104/6) securing horizontal arm to rear housing. Tighten screws.
IMPORTANT: It is now safe to release axis brakes.
3. Install connections for horizontal arm.
Following points refer to illustration in figure 41.
a. Install ground connection (41/3).

b. Install 3 connectors for measuring system:

Important: Measuring system connectors must be installed correctly in relation
to the respective axes.
c. Install motor connector (41/5) on bracket. (Some old versions may have a power
connector for each motor, they must be installed correctly in relation to the
respective axes).
d. Install purge sensor connector and attach air hose.
4. Conclude operation
a. Install rear housing cover (104/1).

6.5 Removal of Motor for Axes 4, 5, 6
LOCATION
The motors for axes 4, 5 and 6 are located in the rear housing of the horizontal arm as
Figure 43 Location of motors
Motor 4
Horizontal arm drive unit
Motor 6 (Motor 5 on opposite side)
REFERENCES
’Removal of Horizontal Arm Drive Unit’ on page 93
TOOLS AND ITEMS

Hand tools
Burndy pin extraction tool
PROCEDURE
Note: The following guidelines are for axis 6 motor removal. Axis 4 and 5 motor
removal procedures are identical unless specifically noted. - Ref: figure 44 for location
of motors.
WARNING!
a. Remove horizontal arm drive unit as described in procedure ’Removal of
Horizontal Arm Drive Unit’ on page 93.
WARNING!
WARNING!

c. Place horizontal arm on a clean work table etc.

d. Remove oil from gear box for axis 4-6. - Ref: ’Replace Oil for Axes 4-6 -
Hollow Wrist Arm’ on page 151 for information.
2. Remove connector bracket.
a. Remove receptacle for measuring system (44/5) from connector bracket. (44/1).
b. Remove motor power receptacle (44/3) from connector bracket.
c. Remove the relevant pins from the power receptacle with a Burndy pin
extraction tool. - Ref: figure 46 for location of pins in receptacle. (Not applicable
for some old versions that have a power connector for each motor).
d. Remove connector bracket (44/1) if necessary (Depending on which motor to be
removed). Bracket is removed by removing 2 e.a. attachment screws.
Figure 44 Axes 4, 5, 6 drive motors
Motor 5 Motor 4 Motor 6

1
3. Remove motor.
a. Loosen motor set screw (44/2) a couple of revolutions.
b. Unscrew 4 motor attachment screws (44/4).
c. Remove motor.

6.6 Installation of Motor for Axes 4, 5, 6
LOCATION
The motors for axes 4, 5 and 6 are located in the rear housing of the horizontal arm as
Figure 45 Location of motors
Motor 4
Motor 6 (Motor 5 on opposite side)
REFERENCES
’Installation of Horizontal Arm Drive Unit’ on page 95
figure 44
TOOLS AND ITEMS

Wrist axes rotor rotating tool
Hand tools
PROCEDURE
Note: The following guidelines are for axis 6 motor installation. Axis 4 and 5 motor
installation procedures are identical unless specifically noted. - Ref: figure 44 for
location of motors.
WARNING!
WARNING!
2. Install new motor.
a. Place motor in correct position on horizontal arm rear flange. If possible with
regard to the cables, place motor so that identification label is facing up. (Motor
can be installed in all four 90° positions).
b. Install 4 motor attachment screws (44/4). Tighten screws lightly.
c. Tighten motor adjustment set screw (44/2) lightly.

3. Align motor.
a. Install screw of rotor rotating tool on rear end of rotor shaft (44/6). Rotate tool
until it stops. Tighten lightly.
IMPORTANT: It is safe to release brakes for the axis motors on the horizontal
arm but NOT on the robot itself.
b. Release axis brakes for motor. - Ref: ’Releasing Axis Brakes’ on page 11.
c. Rotate rotor a number of revolutions until finding the point where the play
between motor shaft gear wheel and gearwheel for wrist drive shaft is at a
minimum. (A full rotation of the motor drive shaft requires
approx. 17 revolutions of the rotor).
d. Tighten motor adjustment set screw (44/2) until no play can be felt.
e. Rotate rotor to feel that the rotor can be freely rotated over the full rotation of the
motor shaft.
f. Tighten motor attachment screws (44/4).
4. Install connections.
a. If connector bracket was removed, re-install bracket.
b. Install measuring system receptacle.
c. Install the power pins of the new motor for axis 4, 5 or 6 to the power receptacle.
- Ref: figure 46 for location of pins in receptacle. (Not applicable for some old
versions that have a power connector for each motor).
Figure 46 Connections in motor receptacle
4 1
Signal Colour Motor 4 Motor 5 Motor 6
Motor 4 Phase U YE 1 9 17
Phase V GN 2 10 18
Motor 5 Phase W PK 3 11 19
PTC GY 4 12 20
PTC GY 5 13 21
Motor 6 Brake YE 6 14 22
Brake YE 7 15 23
24 Gnd GN/YE 8 16 24
Mating face of connector on motors
d. Install power receptacle on bracket.

a. Refill oil in gear box. - Ref: ’Replace Oil for Axes 4-6 - Hollow Wrist Arm’ on
b. Install horizontal arm drive unit as described in procedure ’Installation of

6.7 Removal of Wrist Transmission Shafts
LOCATION
The wrist transmission shafts are located in the horizontal arm as shown in the figure
below.
Figure 47 Location of wrist transmission shafts
Axis 4, 5, 6
drive motors
Hollow wrist
Axis 4, 5, 6 wrist transmission shafts
REFERENCES
’Removal of Wrist Unit’ on page 136
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
b. Remove horizontal arm drive unit as described in procedure ’Removal of
c. Remove oil from gear box for axis 4-6. - Ref: ’Replace Oil for Axes 4-6 -
d. Remove wrist. Refer to ’Removal of Wrist Unit’ on page 136.
2. Remove motor unit.

Figure 48 Horizontal arm motor unit
a. Knock out guide pin (48/2) by knocking horizontal arm rear housing guide pin
(48/3) forwards.
b. Remove 4 screws (48/1) securing motor unit to horizontal arm.
c. Remove motor unit.
3. Remove drive shafts.
Figure 49 Drive shaft and gear wheel
Axis 4
Axis 5 1
Axis 6
2
a. Remove 3 pair of screws (49/1) securing ball bearings for axis 4, 5 and 6 drive
shafts. Screws are reached through holes (49/2) in drive shaft gear wheels. (Only
gear wheel for axis 6 is shown in illustration). Rotate gear wheels as required to
align with screws.

b. Pull out all 3 drive shafts. Knock carefully with a plastic hammer at front to free
shaft bearings.
c. Remove drive shafts. Note that the 3 drive shafts have different lengths. In
addition, the drive shaft for axis 4 (center drive shaft) has a shorter distance
between the gear wheel and the bearing.

6.8 Installation of Wrist Transmission Shafts
LOCATION
below.
Axis 4, 5, 6
drive motors
Hollow wrist
REFERENCES
’Installation of Wrist Unit’ on page 138
’Installation of Motor for Axes 4, 5, 6’ on page 99
figure 48
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Install new drive shafts.
a. Add a little grease to each of the 3 radial seals (49/3).
b. Enter the drive shafts into their respective radial seal. Be careful not to damage
the seals.
Important. A damaged radial seal must be replaced. If not inner oil leaks will
occur.
c. Bring the 3 shaft gear wheels together and push all 3 drive shafts through
horizontal arm.

NOTE. The 3 shafts are different and can be identified as follows: Axis 4 shaft
has a shorter distance between the gear wheel and the ball bearing. Axis 5 shaft
is longer than axis 6 shaft. Refer to figure 49 for location of the axes.
d. While guiding the drive shafts at the front of the horizontal arm, push the drive
shafts fully into position. Carefully knock on the shafts using a plastic hammer if
required.
e. Install 3 pairs of screws (49/1) securing ball bearings. Rotate gear wheels as
required for access.
3. Install motor unit.
a. Knock guide pins (48/2) on horizontal arm flange into position by knocking
from the front.
b. Check that o-ring on front of the motor unit is undamaged and properly
positioned. Install motor unit.
Note. You may have to wiggle motor unit and drive shafts to align tooth of gear
wheels as an alternative to releasing the brakes for the motors.
c. Install screws (48/1) securing motor unit to horizontal arm. Tighten screws.
d. Check that gear box is properly sealed before filling oil. This can be checked by
connecting pressurised air and gauge to the filling hole. Apply 0.5 Bar and check
that no leaks can be observed. If leaks are present, try to locate leaks using water
and soap. Correct leak by replacing o-ring between drive unit and horizontal arm
flange or replace radial seal as necessary.
e. Refill oil in gear box. - Ref: ’Replace Oil for Axes 4-6 - Hollow Wrist Arm’ on
a. Install horizontal arm drive unit as described in procedure ’Installation of
b. Install wrist. Refer to ’Installation of Wrist Unit’ on page 138.
c. Check alignment of drive motors. Refer to ’Installation of Motor for Axes 4, 5,
6’ on page 99.


7 H40 Horizontal Arm Guidelines

Following procedures provide information for replacing components on the H40
horizontal arm (process arm). For identification of H40 horizontal arm see ’Component
Overview’ on page 10.

7.1 Removal of Horizontal Arm
LOCATION
Upper bevel gear

Horizontal arm
REFERENCES
figure 104
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
c. Remove vertical arm front cover (104/14).
WARNING!
2. Disconnect cables and hoses.
a. Follow cables for horizontal arm from top of the vertical arm to their respective
connections. Disconnect connectors.

Note: Before disconnecting any connectors, ground wires or cable straps,

carefully note position to ensure correct re-installation.
b. Remove screws (106/3) securing the two cable hoses to vertical arm top.
c. Pull out both cable units.
d. Disconnect paint- and air supply hoses as required.
3. Remove arm attachment to bevel gear.
a. Remove 2 blind screws (106/1) on outside of bevel gear unit.
b. Release brakes for axis 3.
c. Move arm to fully upper position. Position arm so that the 2 attachment screws
are accessible through the holes where the blind plugs were removed.
d. Activate brakes.
e. Remove screws (106/8) securing horizontal arm end housing to bevel gear unit.
The screws are reached from the outside of the bevel gear unit. Retain screws for
re-installation.
f. Release brakes for axis 3 and move horizontal arm a little downwards to get
access to next 2 screws. Activate brakes and remove screws. Repeat this
operation until 8 screws have been removed (2 screws remain attaching the
horizontal arm to the bevel gear).
g. Release brakes for axis 3 for the last time.
h. Before untightening the last two screws, release spring tension for axis 3 as
described in ’Disengage Balancing Spring’ on page 36.
Note: If the repair work is limited to the horizontal arm itself, the
counterbalance spring for axis 3 may stay engaged.
i. Position remaining screws so they are accessible. Activate brakes.
j. Disable the axis brake release function and mark brake release function to
prevent releasing the brakes by accident.
WARNING!
k. Suspend horizontal arm to prevent the arm from falling when removing arm
attachment.
CAUTION: The horizontal arm is heavy (approximately 80 kg). Make sure that
arm is properly suspended before removing attachment screws.
WARNING!
Do not continue unless arm is properly suspended.
l. Mark position of arm and remove the last 2 screws.

Note. The horizontal arm may stick very hard on the joint to the bevel gear
(aluminium against steel). Before removing the left side arm attachment, the
horizontal arm should be moved up/down to free the joint. Note that
considerable force may be required to free the joint.
4. Remove left side arm attachment.
a. Move the horizontal arm to a position where it hangs straight down.
b. Remove 4 screws (106/10) from clamp ring on left side of horizontal arm rear
housing.
c. Pull out clamp ring (106/11) by hand.
WARNING!
Do not continue unless arm is properly suspended. The arm will fall when the
bearing bolt is removed in the next step
d. Using a plastic hammer or hammer and dowel etc. carefully knock out bearing
bolt (106/12) from the outside and inwards until arm is free.
e. Remove horizontal arm assembly.

7.2 Installation of Horizontal Arm
LOCATION
Upper bevel gear

Horizontal arm
REFERENCES
figure 104
figure 106
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Attach horizontal arm to left side attachment.
a. Lift horizontal arm into position on bevel gear.
b. Place bearing bolt (106/12) into position.
c. Install clamp ring (106/11) and secure with 4 screws (106/10).
3. Secure horizontal arm to bevel gear.
a. Move horizontal arm to correct position in accordance with marking, etc., made
during removal.

b. Install first 2 screws (106/8) securing horizontal arm rear housing to bevel gear
unit. The screws are installed from the outside of the bevel gear unit, through the
blind plug holes. Tighten screws. It is important that these screws are tightened
with correct torque, see ’Tightening Torques’ on page 16.
c. If balancing springs have been disengaged, re-apply spring tension for axis 3 as
described in ’Engage Balancing Spring’ on page 39.
IMPORTANT: After engaging axis 3 balancing spring, it is safe to release the
brakes.
d. Release brakes for axis 3. Move horizontal arm up/down to get access to the next
2 screws. Activate brakes.
e. Install screws and tighten as described above.
f. Repeat this operation for all screws.
g. Install blind screws (106/1) in bevel gear.
4. Connect cables and hoses.
a. Route both electrical cable hoses into holes on top of the vertical arm. Install
attachment screws (106/3) and secure.
b. Lead electrical cables down into vertical arm and connect according to markings
made during removal.
c. Connect paint- and air supply hoses as required.
a. Refill oil in bevel gear unit (106/2). Refer to ’Replace Oil in Bevel Gears’ on
b. Install vertical arm cover (104/14).

7.3 Removal of Horizontal Arm Drive Unit

This procedure describes replacement of the horizontal arm drive unit. This means the
complete horizontal arm except for the rear housing.
LOCATION
below.
Figure 53 Horizontal arm drive unit, robot right side view
Rear housing cover
REFERENCES
figure 104
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
a. Release axis brakes. Move vertical arm to vertical position and horizontal arm to
horizontal position. Activate brakes.
WARNING!
c. Open horizontal arm rear housing cover (104/1). The purge sensor is mounted
on the inside of the cover.
2. Remove connections for horizontal arm.

a. Disconnect purge sensor connector, pull off air hose for purge sensor and
remove cover.
Note: Before disconnecting any connectors, ground wires or cable straps,
carefully note position to ensure correct re-installation, see also figure 54.
b. Disconnect ground connection.
Figure 54 Electrical connections, horizontal arm rear view
Pump motor 2 Pump motor 1
1 4
11 5
2 10
Axis motor 5 Axis motor 4
6
Axis motor 6 7
8
9
c. Disconnect axis motor 4, 5, 6 connections:

Disconnect 3 connectors for measuring system:
Disconnect connector for motor power (54/3).
d. Disconnect pump motor connections as required, 1 or 2 pump motors might be
installed:
Disconnect connector(s) for measuring system:
Pump motor 1 (54/5) and pump motor 2 (54/1)
Disconnect connector(s) for motor power:
Pump motor 1 (54/4) and pump motor 2 (54/2).
WARNING!
3. Remove horizontal arm drive unit.
a. Suspend horizontal arm drive unit (104/7) using a lifting strap, etc.

CAUTION: The horizontal arm drive unit is heavy (approximately 67 kg).

Make sure that arm is properly supported before removing attachment screws.
b. Unscrew the 6 screws (104/6) securing horizontal arm drive unit to rear housing.
c. Remove horizontal arm drive unit by carefully pulling it straight-forward out of
the rear housing,

7.4 Installation of Horizontal Arm Drive Unit
LOCATION
below.
Figure 55 Horizontal arm drive unit, robot right side view
Rear housing cover
REFERENCES
figure 54
figure 104
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Install horizontal arm.
a. Place horizontal arm into position on front of the rear housing.
b. Install screws (104/6) securing horizontal arm to rear housing. Tighten screws.
3. Install connections for horizontal arm.
a. Install ground connection.

b. Connect axis motor 4, 5, 6 connections:

Connect 3 connectors for measuring system:
Connect connector for motor power (54/3).
IMPORTANT: Measuring system connectors must be installed correctly in
relation to the respective axes. Refer to markings made during removal and
figure 54 for identification of connections.
c. Connect pump motor connections, 1 or 2 pump motors might be installed:
Connect connector(s) for measuring system:
Connect connector(s) for motor power:
IMPORTANT: Motor- and measuring system connectors must be installed
correctly in relation to the respective pumps. Refer to markings made during
removal and figure 54 for identification of connections.
d. Connect purge sensor connector and attach air hose. (The purge sensor is
mounted on the inside of the rear housing cover).
4. Conclude operation
a. Install rear housing cover (104/1).

7.5 Removal of Motor for Axes 4, 5, 6 and Pump Motor 1, 2
LOCATION
The motors are located in the rear housing of the horizontal arm as shown in the figure
below.
Figure 56 Location of motors, robot right side view
Pump motor 1 (Motor 2

on opposite side)
Motor axis 4 (Motor

axis 5 on opposite side)
Motor axis 6
REFERENCES
TOOLS AND ITEMS

Hand tools
Burndy pin extraction tool
PROCEDURE
Note: The following guidelines are for axis 5 motor removal. Axis 4, 6 motor and pump
motor 1, 2 removal procedures are identical unless specifically noted. - Ref: figure 54
and figure 57 for location of motors.
WARNING!
a. Remove horizontal arm drive unit as described in procedure ’Removal of
WARNING!
WARNING!

c. Place horizontal arm drive unit on a clean work table, etc.

d. Remove oil from gear box for axis 4-6. For information, refer to ’Replace Oil for
Axes 4-6 - Hollow Wrist Arm’ on page 151.
2. Remove connections.
a. Remove receptacle for measuring system axis 5 (54/7) from connector bracket.
For axis 4 motor removal: (54/6).
For axis 6 motor removal: (54/8).
For pump motor 1 removal: (54/5).
b. Remove motor power receptacle (54/3) from connector bracket.
For axis 4 and 6 remove the same receptacle (54/3).
c. For axes 4, 5 and 6 motor, remove the relevant pins from the power receptacle
(54/3) with a Burndy pin extraction tool. (The power wires for all 3 motors are
connected to 1 receptacle). - Ref: figure 59 for location of pins in receptacle.
d. Remove connector bracket (54/9), (54/10) or (54/11) if necessary (depending on
which motor to be removed). Bracket is removed by removing 2 e.a. attachment
screws.
3. Remove motor.
a. Unscrew 4 motor attachment screws (57/1).
Figure 57 Axes 4,5,6 drive motors
1
Motor axis 4
Motor axis 5
Motor axis 6
b. Remove motor.

7.6 Installation Motor for Axes 4, 5, 6 and Pump Motor 1, 2
LOCATION
The motors are located in the rear housing of the horizontal arm as shown in the figure
below.
Figure 58 Location of motors, robot right side view
Pump motor 1 (Motor 2

on opposite side)
Motor axis 4 (Motor

axis 5 on opposite side)
Motor axis 6
REFERENCES
figure 57
TOOLS AND ITEMS

Wrist axes rotor rotating tool
Hand tools
PROCEDURE
Note: The following guidelines are for axis 5 motor installation. Axis 4 and 6 motor and
pump motor 1, 2 installation procedures are identical unless specifically noted. - Ref:
figure 54 and figure 57 for location of motors.
WARNING!
WARNING!
2. Install new motor.
a. Place motor in correct position on horizontal arm rear flange. If possible, with
regard to the cables, place motor so that identification label is facing up. (Motor
can be installed in all four 90° positions). Possibly release axis brakes for the
motor to simplify the installation. - Ref: ’Releasing Axis Brakes’ on page 11.

b. Install 4 motor attachment screws (57/1). Add loctite 243 to screws (57/3).
Tighten screws lightly.
3. Align motor.
a. Install screw of rotor rotating tool on rear end of rotor shaft (57/2). Rotate tool
until it stops. Tighten lightly.
b. Release axis brakes for motor. - Ref: ’Releasing Axis Brakes’ on page 11.
IMPORTANT: It is safe to release brakes for the axis motors 4, 5 and 6 on the
horizontal arm. Do not release the robot brakes (axes 1-3).
c. Rotate rotor a number of revolutions until finding the point where the play
between motor shaft gear wheel and gear wheel for wrist drive shaft is at a
minimum. (A full rotation of the motor drive shaft requires
approx. 17 revolutions of the rotor).
d. Loosen motor attachment screws (57/1) a little until the motor can be moved.
Slightly adjust the motor until no play can be felt. Tighten screws lightly.
e. Rotate rotor to feel that the rotor can be freely rotated over the full rotation of the
motor shaft.
f. Tighten motor attachment screws (57/1).
4. Install connections
a. If connector bracket was removed, re-install bracket.
b. Install measuring system receptacle (54/7).
For axis 4 motor installation: (54/6).
For axis 6 motor installation: (54/8).
For pump motor 1 installation: (54/5).
For pump motor 2 installation: (54/1).
c. Install the power pins of the new motor for axis 4, 5 or 6 to the power receptacle.
- Ref: figure 59 for location of pins in receptacle.
Figure 59 Connections in motor receptacle
4 1
Signal Colour Motor 4 Motor 5 Motor 6
Motor 4 Phase U YE 1 9 17
Phase V GN 2 10 18
Motor 5 Phase W PK 3 11 19
PTC GY 4 12 20
PTC GY 5 13 21
Motor 6 Brake YE 6 14 22
Brake YE 7 15 23
24 Gnd GN/YE 8 16 24
Mating face of connector on motors

d. Install power receptacle (54/3) on bracket (54/9).

For pump motor 1 install power receptacle (54/4) on bracket (54/10).
For pump motor 2 installation: (54/2) on bracket (54/11).
a. Refill oil in gear box. - Ref: ’Replace Oil for Axes 4-6 - Hollow Wrist Arm’ on
b. Install horizontal arm drive unit as described in procedure ’Installation of

7.7 Removal of Wrist Transmission Shafts
LOCATION
below.
Pump motors
Motor axis 4, 5, 6
Hollow wrist
REFERENCES
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
b. Remove horizontal arm drive unit as described in procedure ’Removal of
c. Remove oil from gear box for axis 4-6. - Ref. ’Replace Oil for Axes 4-6 -
d. Remove wrist. Refer to ’Removal of Wrist Unit’ on page 136.
2. Remove motor unit.

Figure 61 Horizontal arm motor unit
a. Knock out guide pins (61/2) and (62/2) on both sides of the motor unit, by
knocking horizontal arm rear housing guide pin forwards.
b. Remove 6 screws (61/1) securing motor unit to horizontal arm.
c. Remove motor unit.
3. Remove drive shafts.
Figure 62 Drive shaft and gear wheel location
Axis 4
Axis 5
Axis 6

a. Remove screws (62/1) securing ball bearings for axis 4, 5 and 6 drive shafts.
Screws are reached through holes in drive shaft gear wheels. Rotate gear wheels
as required to align with screws.
b. Pull out all 3 drive shafts. Knock carefully with a plastic hammer at front to free
shaft bearings.
c. Remove drive shafts. Note that drive shaft 5 is shorter than drive shaft 4 and 6.
In addition, the drive shaft for axis 6 (center drive shaft) has a longer distance
between the gear wheel and the bearing.

7.8 Installation of Wrist Transmission Shafts
LOCATION
below.
Pump motors
Motor axis 4, 5, 6
Hollow wrist
REFERENCES
’Installation Motor for Axes 4, 5, 6 and Pump Motor 1, 2’ on page 120
figure 61
figure 62
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Install new drive shafts.
a. Add a little grease to each of the 3 radial seals (62/3).
b. Add a little Loctite 270 to each of the bearings.
c. Enter the drive shafts into their respective radial seal. Be careful not to damage
the seals.
IMPORTANT. A damaged radial seal must be replaced. If not inner oil leaks
will occur.

d. Bring the 3 shaft gear wheels together and push all 3 drive shafts through
horizontal arm. Refer to figure 62 for location of the axes. Note that drive shaft 5
is shorter than drive shaft 4 and 6. In addition, the drive shaft for axis 6 (center
drive shaft) has a longer distance between the gear wheel and the bearing.
e. While guiding the drive shafts at the front of the horizontal arm, push the drive
shafts fully into position. Carefully knock on the shafts using a plastic hammer if
required.
f. Install screws (62/1) securing ball bearings. Rotate gear wheels as required for
access.
3. Install motor unit.
a. Knock guide pins (61/2) and (62/2) on horizontal arm flange into position by
knocking from the front.
b. Check that o-ring on front of the motor unit is undamaged and properly
positioned. Install motor unit.
Note. You may have to wiggle motor unit and drive shafts to align tooth of gear
wheels as an alternative to releasing the brakes for the motors. - Ref: ’Releasing
Axis Brakes’ on page 11.
c. Install screws (61/1) securing motor unit to horizontal arm. Tighten screws.
d. Check that gear box is properly sealed before filling oil. This can be checked by
connecting pressurised air and gauge to the filling hole. Apply 0.5 Bar and check
that no leaks can be observed. If leaks are present, try to locate leaks using water
and soap. Correct leak by replacing o-ring between drive unit and horizontal arm
flange or replace radial seal if necessary.
e. Refill oil in gear box. For information refer to ’Replace Oil for Axes 4-6 -
a. Install horizontal arm drive unit as described in procedure ’Installation of
b. Install wrist. Refer to ’Installation of Wrist Unit’ on page 138.
c. Check alignment of drive motors. Refer to ’Installation Motor for Axes 4, 5, 6
and Pump Motor 1, 2’ on page 120.

7.9 Removal of Function Valve Module
LOCATION
The function valve module is located in the rear end of the horizontal arm as shown in
the figure below.
Figure 64 Location of function valve module
Function valve module
REFERENCES
No references
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
IMPORTANT: Before performing this operation, the robot purging system has to
be shut off. This also means that all electrical power to the manipulator will be
switched off.
WARNING!

Figure 65 Function valve module located on the rear part of horizontal arm
b. Disconnect the cover grounding wire and remove the horizontal arm cover.
c. Remove the left side vertical arm cover.
2. Remove air hoses.
a. Shut off the air pressure supply to the function valve module.
b. Disconnect the air hoses (65/1), checking that they are correctly marked.
3. Remove function valve module.
a. Remove the bolts, securing the module to the horizontal arm. Be careful not
dropping the module when removing the last bolt.
b. Carefully, pull the function valve module (65/2) out of the robot arm.
c. The electrical connector (65/3) can be disconnected when the module is partly
pulled out. The number of plugs depends on the number of valve blocks installed
in each module.

7.10 Installation of Function Valve Module
LOCATION
The function valve module is located in the rear end of the horizontal arm as shown in
the figure below.
Figure 66 Location of function valve module
Function valve module
REFERENCES
No references
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Install new function valve module.
a. Connect the electrical connectors at their correct position. Make sure that the
connectors are properly inserted in the sockets.
b. Tighten the bolts, securing the function valve module to the horizontal arm. The
holes in the horizontal arm are ‘purged area’. Therefore, it is important that all
bolts are properly tightened.
c. Reconnect the air hoses at their correct position.
a. Reinstall the covers.
b. Reconnect the cover grounding wire.

7.11 Removal of Gear Pump
LOCATION
The gear pump is located in the horizontal arm as shown in the figure below.
Figure 67 Location of gear pump
Gear pump
REFERENCES
No references
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!

Figure 68 Gear pump located on process robot horizontal arm
b. Open the horizontal arm cover.

c. Check that the pump is flushed with solvent.
d. Check that all paint and solvent valves are closed.
e. Evacuate trapped pressure from the system.
2. Remove gear pump.
a. Loosen the four bolts on top of the pressure sensor block (68/1).
b. Loosen the two bolts, one on each side of the pump mounting plate (68/2).
c. Carefully remove the gear pump (68/3) from the robot arm, preventing the shaft
coupling ring from falling off the pump shaft.

7.12 Installation of Gear Pump
LOCATION
The gear pump is located in the horizontal arm as shown in the figure below.
Figure 69 Location of gear pump
Gear pump
REFERENCES
No references
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Install new gear pump.
a. Install the new pump by aligning it with the shaft coupling and the slots in the
mounting plate.
b. Before tightening the bolts, check the free play in the shaft coupling to be a
minimum of 2 mm.
c. Align the pressure sensor block with the gear pump. Make sure that the
alignment pins are in the correct positions before tightening the bolts.
d. Tighten the shaft seal nut according to the instructions described in the ‘Unit
Description - Paint’ manual.

a. Close and secure the horizontal arm cover.

Hollow Wrist Unit Guidelines
8 Hollow Wrist Unit Guidelines

Following procedures provide information for replacing components on the hollow wrist
unit.

8.1 Removal of Wrist Unit
LOCATION
The wrist is located at the front of the horizontal arm as shown in the figure below.
Figure 70 Location of hollow wrist
H40 Horizontal arm Hollow wrist
H10 Horizontal arm

Hollow wrist
REFERENCES
No references
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Remove wrist.
a. Remove 8 screws securing wrist flange to front of horizontal arm. The location
of the screw attachment holes on the front of the horizontal arm is shown in the
illustrations below, (71/3) or (72/3).

Figure 71 Wrist unit rear end and standard arm front
5
2
6
Figure 72 H40 horizontal arm front
1 5
b. Grip wrist with both hands (Weight approximately 15 kg). Hold wrist firmly and
wiggle from side to side to remove.
c. If ball bearing (71/5)/(72/5) needs replacement, remove bearing using a puller.

8.2 Installation of Wrist Unit
LOCATION
The wrist is located at the front of the horizontal arm as shown in the figure below.
Figure 73 Location of hollow wrist
H40 Horizontal arm Hollow wrist
H10 Horizontal arm

Hollow wrist
REFERENCES
figure 71
figure 72
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Install wrist.
a. If bearing (71/5)/(72/5) was removed, add grease to inside of bearing. Add a
little Loctite 270 on inner ring, place bearing in position and carefully knock into
position using a plastic hammer. Make sure that bearing is properly positioned.
b. Lubricate front of ball bearing (71/4)/(72/4).
c. Lubricate gear wheels on wrist and horizontal arm (71/1)/(72/1).

d. Lubricate o-ring (71/2) and inside of hole (71/6)/(72/6) in horizontal arm front.
e. Hold wrist with both hands and place it into position on horizontal arm front.
Wiggle wrist carefully to get all gears into grip. Push wrist fully into position.
f. Install 8 attachment screws and tighten.
a. Calibrate the robot as described in ’Calibration Procedure’ on page 173.

8.3 Removal of Wrist Inner Flexible Hose
LOCATION
The wrist inner flexible hose is located in the wrist unit as shown in the figure below.
Figure 74 Wrist unit, right side view
Inner flexible hose

Horizontal arm
Hollow wrist
REFERENCES
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
b. Remove spray-gun, gun attachment and supply hoses as required.
Note: If wrist can be removed and re-installed without changing the position of
any of the 3 joints, calibration will not be required. Mark position of wrist and
all joints as required to make sure that they are not moved.
c. Remove wrist from horizontal arm as described in ’Removal of Wrist Unit’ on
page 136.
d. Place wrist on a clean workbench with the front facing up.
2. Remove flexible hose.

Figure 75 Wrist unit, front end
2 1 1
a. Loosen 2 screws (75/2) securing front ring (75/1) of flexible hose to front of
wrist. Do not remove screws.
b. Grab front ring (75/1) with fingers to feel that the ring is free.
c. Turn wrist unit upside down so that it is now standing on its front end.
d. Refer to figure 76 and place 2 e.a. medium size screwdrivers under flange of
flexible hose rear plastic ring.
Caution. Be careful not to damage o-ring (76/2).
e. Press both screwdrivers down to remove ring (76/1) from wrist.
Figure 76 Wrist unit, rear end

1 2
Screwdriver Screwdriver
1 2
f. Pull flexible hose out from rear end of wrist.
g. Discard old flexible hose.

8.4 Installation of Wrist Inner Flexible Hose
LOCATION
The wrist inner flexible hose is located in the wrist unit as shown in the figure below.
Figure 77 Wrist unit, right side view
Inner flexible hose

Horizontal arm
Hollow wrist
REFERENCES
figure 75
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Install new flexible hose.
a. Lubricate flexible hose.
b. Slide new hose into wrist from the rear end. Press hose as far down as practical.
c. Turn wrist upside down so that front is facing up.
d. Pull flexible hose up with fingers until front of ring is aligned with inner flange
of wrist front ring.
e. Tighten flexible hose retaining screws (75/2).
f. Turn wrist so that rear end is facing up.

g. Insert hose retaining ring and carefully knock into position using a plastic
hammer.
a. Install wrist on horizontal arm as described in ’Installation of Wrist Unit’ on
page 138.
b. If required, calibrate the robot as described in ’Calibration Procedure’ on page
173.
c. Install spray-gun, gun attachment and supply hoses as required.

8.5 Replacing Wrist Seals

The following procedure describes how to replace the seals for the hollow wrist. The
wrist has 4 seals which must be replaced when worn.
LOCATION
The wrist seals are located on the wrist unit as shown in the figure below.
Figure 78 Hollow wrist seals
2 3 4 5
1 Hollow wrist
2 Rear seal
3 Axis 6 rear seal
4 Axis 6 front seal
5 Front seal
6 Pin
REFERENCES
No references
TOOLS AND ITEMS

Hand tools
PROCEDURE
WARNING!
WARNING!
2. Remove old seals.

a. Carefully, not to damage the seal seat, insert a screwdriver between seal and seal
seat.
Note: Before removing the front seal, remove pin (78/1) using a pair of pliers.
b. Remove seal.
c. Repeat operation for all seals to be removed.
3. Install new seals.
a. Add a little grease to seal seat.
IMPORTANT: Be careful not to damage the seals during handling and
installation.
b. Install new seal, making sure that seal is installed in correct direction. Ref.
figure 78 for information.
c. Repeat operation for all seals.
Note: If front seal has been replaced, re-install pin (78/1).


Oil Change in Gear Boxes
9 Oil Change in Gear Boxes

The following sections provide information for replacing oil in the gear boxes.

9.1 Replace Oil for Axes 1, 2, 3
Figure 79 Location of oil plugs axes 1, 2, 3
Filling plug - Axis 2 gear box

(opposite side)
Filling plug
- Axis 1 gear box
Filling plug - Axis 3 gear box
'Drain plug' - Axis 3 gear box
'Drain plug' - Axis 2 gear box

(opposite side)
Oil specification
Oil type: Ref. ’Oil Type Specifications’ on page 18.
Quantity: Axis 1: 10.0 liter
Axis 2: 4.8 liter
Axis 3: 4.8 liter
Level: All axes, 0-20 mm below filling hole
Note: Oil quantity refers to an empty, clean gear box. Later refilling will require a lower
quantity.
1. Remove oil.
a. Place a suitable container with sufficient volume on the floor.
b. Remove filling/drain plug for required axis.
Note. The ‘drain plug’ for axis 2-3 was introduced winter-02 to enable partly
draining of the gear box (to prevent oil spill during motor replacement). To drain
oil completely, oil must still be pumped out using the most convenient plug.
For axis 1, oil must be pumped out via filling plug.
c. Drain as much oil as possible using the ‘drain plug’ and/or pump out oil using a
suitable pump and hose.
2. Fill new oil.
a. For axis 2-3, clean ‘drain plug’. Re-install plug and tighten.
b. Fill oil until oil level is as specified.
c. Clean filling plug. Re-install plug and tighten.
Note: Oil drained from the manipulator must be disposed of in accordance with local
regulations.

9.2 Replace Oil in Bevel Gears
Figure 80 Location of oil plugs for bevel gears
Filling upper gear
Approx. 30°
Filling lower gear

Draining lower gear
Approx. 30°
Draining upper gear
Oil specification
Quantity: Upper bevel gear: 1.3 liter
Lower bevel gear: 1.5 liter
Level: 0-10 mm below filling hole
quantity.
1. Remove oil.
a. Release axis brakes. For upper gear box, move vertical arm to approx. 30°
backwards position. For lower gear box, move vertical arm to approx. 30°
forwards position.
b. Activate brakes.
c. Place a tray or similar under oil plug.
d. Remove plug and drain oil.
Important: Leave the draining for a period of time. It is important that all the
oil is drained from the gear.
2. Fill new oil.
a. Release axis brakes. For upper gear box, move arm to fully forward position. For
lower gear box, move arm to fully backwards position.

b. Activate brake.
c. Fill oil in the gear unit.
Upper bevel gear: Fill oil until oil level is as specified. It is important that the
correct amount of oil is filled in this bevel gear. (Too little oil will not ensure
proper lubrication, and too much oil may cause oil leaks).
Important: It is important not to fill too much oil in upper gear, as increased
temperature will expand oil which can cause leaks.
Lower bevel gear: Fill oil until oil level is as specified. (This gear box is includes
an inside accumulator, and is thereby not critical to overfilling).
d. Clean plug. Re-install plug and tighten.
e. Release axis brake for axis 2 and move vertical arm back to vertical position.
f. Activate brake.
regulations.

9.3 Replace Oil for Axes 4-6 - Hollow Wrist Arm
Figure 81 Location of oil plugs axes 4-6, hollow wrist arm

Filling plug
axis 4-6 gear box
H10 Horizontal arm
Drain plug axis 4-6 gear box (2 e.a. plugs)

Not available on later versions
of the H10 arm
Filling plug
axis 4-6 gear box
H40 Horizontal arm
Drain plug
axis 4-6 gear box
(2 e.a. plugs)
Oil specification
Quantity: H10 - 1.0 liter
H40 - 1.8 liter
Level: H10 - 0-20 mm below filling hole
H40 - 65-75 mm below filling hole
quantity.
1. Remove oil.
a. Release axis brakes and place the horizontal arm in horizontal position. Activate
brakes.
b. Place a tray or similar under oil drain plugs underneath horizontal arm.
c. For H10 horizontal arm: Remove both drain plugs and drain oil. Both drain
plugs must be removed to remove oil from both chambers in the gear box.
For H40 horizontal arm: Remove one drain plug and drain oil.
Note. Later versions of the H10 arm does not include drain plugs. In this
situations, oil must either be drained via the filling plug using a plastic hose and
pump etc., or if the arm is removed for repair, by placing the arm upside/down.
d. Clean drain plugs. Re-install plugs and tighten.
2. Fill new oil.
a. Remove filling plug on top of gear box.

b. Fill oil until oil level is as specified.

c. Clean filling plug. Re-install plug and tighten.
regulations.

Replacing Cable Units
10 Replacing Cable Units

Following procedures provides information for replacing cable units in the IRB 5400-0x
robots.

10.1 Removal of Cables Foot Unit - Base Unit

LOCATION
The cables between the foot unit and the base unit are located on the robot as shown in
the figure below.
Figure 82 Cables foot unit - base unit
Axis motor 2 compartment

(on opposite side)
Base top center compartment
Foot unit top cover
REFERENCES
No references
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note. This procedure also applies for a robot mounted on a trolley. Connections inside
the trolley corresponds to connections inside the foot unit. For location of panels on the
trolley, see separate trolley manual.
WARNING!
a. Place robot in a convenient position to get access to all covers at the base unit
(84/L,R,T) and the cover at the foot unit (84/F).

b. Turn electrical disconnect switch ‘off’ and lock switch in ‘off’ position.
WARNING!
c. Remove foot unit top cover, or electrical compartment cover on trolley foot unit.
d. Remove covers for motor 1, 2, 3 compartment and base top center compartment.
note position to simplify correct installation of new cable.
a. If applicable, disconnect and remove back-up battery in foot unit. Retain battery
for re-installation.
b. Disconnect all connectors from the termination bracket in foot unit.
c. Disconnect the motor power connector, cable clamps and ground wire in base
unit right side compartment (84/R).
d. Disconnect relevant connectors and cable clamps in base top rear
compartment (84/T).
e. Disconnect relevant receptacles and cable clamps located at bracket underneath
motor in base unit left side compartment (88/L). To remove the receptacles first
disconnect the corresponding connectors.
f. If applicable, disconnect relevant remaining connectors in base unit left side
compartment.
3. Remove cable/hose harness.
a. Remove cable strap located just above cable hose in base top center
compartment (84/A).
b. Remove hose nut securing cable hose to base unit by hand, no tool is required.
c. Loosen hose nut in foot unit by hand and lift hose out of the termination bracket.
The 2 nuts/screws securing the termination bracket are now visible, remove
these 2 nuts/screws.
d. Pull out complete cable/hose harness, start with termination bracket in foot unit.
e. Discard old cable/hose harness, including termination bracket.

10.2 Installation of Cables Foot Unit - Base Unit
LOCATION
The cables between the foot unit and the base unit shall be located on the robot as shown
in the figure below.
Figure 83 Cables foot unit - base unit

(on opposite side)
Foot unit top cover
REFERENCES
figure 88
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note. This procedure also applies for a robot mounted on a trolley. Connections inside
the trolley corresponds to connections inside the foot unit. For location of panels on the
trolley, see separate trolley manual.
WARNING!
a. Turn electrical disconnect switch ‘off’ and lock switch in ‘off’ position.
WARNING!

2. Install cable/hose harness.

a. Route the cable ends with the A11-13 connectors from foot unit into hose
entrance to base top center compartment (84/A) and subsequently into base unit
right side compartment (84/B,R). Lay cables with A12 connectors closest to the
center.
b. Install bracket (84/8) on hose with nut (84/10).
c. Install 2 cable clamps (84/6,9) on hose bracket.
d. Move hose fully into position in base unit.
e. Install hose bracket with 2 e.a. screws (84/7) in base top center compartment.
f. Align cables, avoid all crossing and twisting in foot unit. Ensure that cables in
foot unit are aligned and that the hose is pointing straight vertical.
g. Install termination bracket in foot unit.
h. Route cables equipped with A12 connectors via base top rear compartment into
base unit left side compartment (88/L).
i. Route cables equipped with A11, AP1 and SMU connectors from base unit right
side compartment into base top rear compartment (84/T).
Note: All connections must be made according to markings on connectors, figure 84
and figure 88.
a. Install receptacles A12 on bracket underneath motor in base unit left side
compartment (88/L). Install p-clips (88/1).
b. Install corresponding connectors of cables from vertical arm (88/L) to the
installed receptacles.
c. Install A12 connector, ground connection (88/3) and p-clip (88/2) on motor in
base unit left side compartment (88/L).
d. Install A11 connectors, ground connection (84/2) and p-clips (84/1 and 3) in
base top rear compartment (84/T).
e. Install A13 connector, ground connection (84/4) and p-clip (84/5) on motor in
base unit right side compartment (84/R).
f. Install relevant connectors to the termination bracket in foot unit.
g. If applicable, install back-up battery in foot unit and connect battery connector.
a. Install covers on base unit and foot unit.

Figure 84 Location overview - Base unit

T
Base top rear compartment
A11-X11
AP1-XP19
1
(P-clip 5)
2
A11-X24
AP1-XS9
3 (P-clip 4)
1SMU1-X7 AP1-XS8
R
Base right side compartment
A12-X21 A11-X24
AP1-XS8
A12-X25
A12-X22
A11-X11 A13-X31
A12-X20
AP1-XS9 A13-X31 1SMU1-X7
A12-X111
AP1-XP19
4
A L
A12-X113
5
(P-clip 5)
T
F B
A
A1-XP8
A1-XP4 A1-X111
A1-X11 6
A1-X12 7
8
A1-X13 A1-X113
9
A1-XS7 A1-X73
10

10.3 Removal of Cables Base Unit - Vertical Arm

LOCATION
The cables between the base unit and the vertical arm are located on the robot as shown
in the figure below.
Figure 85 Cables base unit - vertical arm
Vertical arm rear cover

Vertical arm rear
compartment
Vertical arm front cover

(on opposite side)
REFERENCES
No references
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for the vertical arm V12. The installation procedure
for the vertical arm V11 is identical unless specifically noted. For identification of
V11/V12 vertical arm see ’Component Overview’ on page 10.
WARNING!
a. Place robot in a convenient position to get access to all covers at the base unit
(84/L,R,T) and the front (if applicable) and rear cover (87/V,S) on the vertical
arm.

WARNING!
c. Remove front and rear covers for vertical arm V12; rear covers for vertical arm
V11.
d. Remove covers for motor 1, 2, 3 compartment..
a. Disconnect relevant connectors, receptacles, ground wire and cable straps in
vertical arm. The receptacles are installed on a bracket. To remove them, first
disconnect corresponding connectors.
b. Disconnect relevant connectors and cable clamps underneath motor in base unit
left side compartment (88/L).
c. Disconnect relevant connectors and cable clamps in base top rear compartment
(87/T).
d. Disconnect relevant ground wire in base unit right side compartment (84/R).
3. Remove cable/hose harness(es).
a. Remove screws securing cable hose(s) to vertical arm (87/1).
b. Remove screws securing hose guide to base unit (87/2).
c. Pull out complete cable/hose harness(es) (87/3).
d. Return old cable/hose harness(es) to ABB AS, Robotics.
e. If applicable, remove connector bracket (87/N), installed beneath MCOB board
in vertical arm.

10.4 Installation of Cables Base Unit - Vertical Arm
LOCATION
The cables between the base unit and the vertical arm shall be located on the robot as
Figure 86 Cables base unit - vertical arm
Vertical arm rear cover

Vertical arm rear
compartment
Vertical arm front cover

(on opposite side)
REFERENCES
figure 88
figure 94
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for the vertical arm V12. The installation procedure
for the vertical arm V11 is identical unless specifically noted. For identification of
V11/V12 vertical arm see ’Component Overview’ on page 10.
WARNING!
WARNING!

2. Install cable/hose harnesses.

a. If applicable, install connector bracket (94/6) beneath MCOB. Secure bracket
with screw.
b. Route new cables with A2 and SMB connectors into hose entrances in vertical
arm (87/1).
c. Route the other cable ends with A11-12 connectors into entrance on top of base
unit into base left side compartment (87/P), (88/L).
d. Move air guide (87/3) in position and secure it to the base unit, install 6
attachment screws (87/2).
e. Move hoses fully into position onto vertical arm and install 4 attachment screws
(87/1).
f. Route relevant cables with A11 connectors from base unit left side compartment
into base top rear compartment (87/T).
Note: All connections must be made according to markings on connectors and
figure 87, figure 88, figure 89 and figure 94.
a. Install A2 connectors (94/G,N), receptacles (94/E,M,N), ground wire (94/3) and
p-clips (94/1,4,5) in vertical arm. Connector X-15.2 is to be installed on MCOB
bracket. Remember to connect the corresponding connectors to the installed
receptacles.
Install connector SMB-X9 on SMU board, see figure 89. If no pumps are
installed in the vertical arm, these connectors are fastened on the rear side.
Install p-clip (89/1).
b. If applicable install connector A2-X150 (94/N).
c. Install A12 connectors (88/L) and p-clips (88/1) underneath motor in base unit
left side compartment.
d. Install A11 connectors in base top rear compartment (87/T).
a. Install covers on vertical arm and base unit.

Figure 87 Location overview - Base unit and vertical arm

C
1
A2-X150 A2-X111
X-15.2 A2-X17
SMB-X9 A2-X16
A2-X44 A2-X1
A2-X42
A2-X5
A2-X40
2
3
V
Vertical arm front view
C
L E G
T
3 M
A11-X24
A12-X22
A12-X111
A11-X4
A11-X5 T A11-X4 A11-X5 A11-X6 A11-X24
A11-X6
A12-X25
A12-X113 A12-X20
Base top rear compartment

Figure 88 Location overview - Base unit left side compartment

L
Base unit left side compartment
A12-X21
A12-X25
A12-X20
(P-clip 5)
A12-X111
2 (P-clip 5)
(P-clip 4)
(P-clip 5)
A12-X22 3
(P-clip 4)
(P-clip 5)
(P-clip 4)
A12-X113
Cables from vertical arm 1 Cables from foot unit
Figure 89 Location overview - Vertical arm rear view

S
SMB-X9 X1_4
1 (P-clip 4) (P-clip 5)
SMB-X9

10.5 Removal of Cables Vertical - Horizontal Arm

LOCATION
The cables between the vertical arm and horizontal arm are located on the robot as
Figure 90 Cables vertical arm - horizontal arm
Horizontal arm - Horizontal arm rear Horizontal arm - Horizontal arm rear
vertical arm compartment vertical arm compartment
cable hose cable hose
H10 Horizontal arm H40 Horizontal arm
Vertical arm
rear cover
Vertical arm
front cover
Vertical arm rear

compartment
REFERENCES
No references
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for vertical arm V12 and horizontal arm H10. The
removal procedures for the V11 vertical arm and the H40 horizontal arm are identical
unless specifically noted. For identification of V11/V12 vertical arm and H10/H40
horizontal arm see ’Component Overview’ on page 10.
WARNING!
a. Place robot in a convenient position, e.g. vertical arm 30° backward and
horizontal arm in horizontal position.

WARNING!
c. Remove front cover for vertical arm V12 and if the robot is equipped with the
H40 horizontal arm also rear cover. Remove rear covers for vertical arm V11.
d. Remove horizontal arm rear cover and disconnect flexible hose and purge
connector from purge sensor. The purge sensor is installed in the horizontal arm
rear housing cover.
For old style first remove the purge sensor out of the horizontal arm rear
housing. Remove screws.
a. Disconnect connectors for measuring system and connectors for motor power
located on bracket at rear end of motor assembly in horizontal arm
(92/X)/(93/X).
b. Remove receptacles for motor connectors from bracket (not applicable for
horizontal arm H40).
c. Disconnect remaining relevant connectors, ground wire and cable straps in
horizontal arm.
d. If applicable, remove connector bracket out of horizontal arm.
e. Disconnect relevant connectors, ground wire and cable straps in vertical arm.
f. If applicable, remove bracket (92/H)/(93/H) out of vertical arm.
3. Remove cable/hose harness(es).
a. Remove screws securing cable hose(s) to vertical- and horizontal arm.
b. Pull out complete cable/hose harness(es). Discard old cable/hose harness(es).

10.6 Installation of Cables Vertical - Horizontal Arm
LOCATION
The cables between the vertical arm and horizontal arm shall be located on the robot as
Figure 91 Cables vertical arm - horizontal arm
Horizontal arm - Horizontal arm rear Horizontal arm - Horizontal arm rear
vertical arm compartment vertical arm compartment
cable hose cable hose
H10 Horizontal arm H40 Horizontal arm
Vertical arm
rear cover
Vertical arm
front cover
Vertical arm rear

compartment
REFERENCES
figure 89
TOOLS AND ITEMS

Hand tools
PROCEDURE
Note: The following guidelines are for the V12 vertical arm and H10 horizontal arm.
The installation procedures for the V11 vertical arm and the H40 horizontal arm are
identical unless specifically noted. For identification of V11/V12 vertical arm and
H10/H40 horizontal arm see ’Component Overview’ on page 10. The H40 horizontal
arm is equipped with a second cable hose.
WARNING!

WARNING!
2. Install cable/hose harness.
a. If applicable, install bracket (93/8) upon motor axis 6 in the process arm rear
compartment.
b. If applicable, install connector bracket in the horizontal arm rear housing. Secure
bracket with 2 screws onto the motor in the middle, motor 4.
c. If applicable, install motor receptacles and their labels on bracket at correct
positions, as shown in (92/X) for slim arm and (93/X) for process arm. Ensure
that the ground wire in each motor power cable is connected to the
corresponding motor, as shown in (93/1).
d. If applicable, install bracket (92/5)/(93/5) in top of vertical arm against the front
side. Not applicable for old style vertical arm.
e. Route new cables with A2 connectors into hose entrance(s) in vertical arm, see
illustration of cable/hose harness for slim arm in figure 92 and for process arm in
figure 93.
f. Route the other cable ends with A3 connectors into entrance(s) in horizontal
arm.
g. Move hose(s) fully into position. Rotate hose (left hose for process arm) in such
a way that the 2 cables with removed isolation, for installation of p-clip
(92/3)/(93/3), are placed on top.
Note: Do not twist the cables in the hose.
h. Install hose attachment screws and secure hose(s) to vertical- (92/2) and
horizontal arm (92/1).
i. Route cables down inside vertical arm. Install rubber p-clips at marked positions
(92/6,7)/(93/6,7). Ensure that cables are free from the drive shaft.
j. Install 4 mm p-clip (92/3)/(93/3), securing 2 cables from vertical arm (those with
removed isolation) onto connector bracket. Use a big washer between p-clip and
screw.
Note: All connections must be made according to markings on connectors,
figure 89, figure 92, figure 93 and figure 94.
a. Install A3 connectors on bracket at rear end of motor assembly in horizontal arm
at their correct positions.
Slim arm: (92/X).
Process arm: (93/X).
b. For slim arm instal purge filter (92/W) in horizontal arm.
c. Install purge sensor connector A3-X54 just before the cover is installed.

d. Install ground connection in horizontal arm (92/4)/(93/4).

e. Install A2 connectors in vertical arm at their correct positions (93/K),
(94/E,M,N).
f. Install X1_4 on SMB board, for location see figure 89.
g. Install p-clips (94/2,4).
a. Install covers on vertical and horizontal arm.

Figure 92 Location overview - Horizontal (Slim arm) / vertical arm

X
Horizontal arm compartment
1 2
S Q
A3-X53 3 4 A3-X41 A3-X43 A3-X54 A3-X63

W
A3-X43
A3-X53
A3-X63 A3-X54
A3-X41
Purge filter
Horizontal arm compartment

Q
V
S Vertical arm front view
7 6
E M
5 6 (P-clip 10) 7 (P-clip 18)

H
A2-X42
A2-X44
A2-X40
A2-X2 A2-X17
Vertical arm compartment

Figure 93 Location overview - Process arm

1 X
A3-X123 Horizontal arm compartment
2
A3-X113
A3-X121
8
K A3-X111
A3-X54
Motor 6
A3-X43
A3-X53
A3-X63
A3-X41
A3-X123
A2-X78 A3-X113
A3-X78
A3-X43
A3-X53
A3-X63
A3-X16
A3-X111 A3-X121
3 (P-clip 4) 4 A3-X16 A3-X78 A3-X6
A3-X41 A3-X6
A3-X54 A3-X110 A3-X110
V Vertical arm front view

S
E M
7 6 7
5 7 (P-clip 24)
A2-X110 6 (P-clip 18)
A2-X78 H
A2-X42 A1_4
A2-X111
A2-X44
A2-X110
A2-X40
A2-X16
A2-X2 A2-X17 AP2-X6

Figure 94 Location overview - Vertical arm

G
X15.2
E
M
A2-X44 A2-X40 AP2-X6 A2-X5 A2-X2 A2-X111 A2-X1 A2-X42 1 2 3

N
A2-X150 A2-X17 A2-X16 4 (P-clip 5) 5 (P-clip 4) 6

Calibration Procedure
11 Calibration Procedure
The following sections provide information for calibrating the robot. The chapter
includes description of what calibration is, important safety aspects and calibration
procedures.
Note. Calibration Fixture Installation guidelines, location of Calibration Marks and
Calibration Position Values are found in chapter ‘Calibration Fixture Installation’ in this
manual.
WARNING!
No calibration work must be performed on the robot before the safety regulations
in ‘Safety Guidelines’ in ‘Introduction’ chapter has been read.
11.1 Safety Precautions

Following points must be read and understood before any calibration work is performed
on the robot.
WARNING!
Calibration of the robot must only be performed by skilled personnel with proper
training.
WARNING!
Changing calibration data are operations which may result in unexpected motion of
the robot or cause the robot to race if performed incorrectly. Following points
MUST therefore be observed when running or starting the robot after having
changed the calibration data.
ALWAYS check that no person or object is within the reach of the robot arm before
applying power to the robot and/or starting the robot.
ALWAYS stand ready by an EMERGENCY STOP before applying power to the
robot and/or starting the robot.
ALWAYS check movement of all robot axes in both directions after calibration has
been performed.
WARNING!
Installing the calibration fixtures involves releasing the axis brakes. Even if the
manipulator is counter balanced, attention must be paid to possible dropping or
raising of the arm, depending on horizontal arm type and weight installed on the
arm.

11.2 Description
11.2.1 General
The control system for the robot needs to know the position and orientation of the tool
centre point (TCP) at any time. This is achieved by maintaining the position of the
manipulator axes. The position of an axis is read by means of a resolver on the motor for
the axis, which holds the position within one motor revolution, and a battery backed
counter which holds the number of motor revolutions.
For the information to make any sense to the controller, the axis position must be set
when the manipulator is placed in a fixed position. The process for doing this is called
calibration. The manipulator is placed in the calibration position by help of calibration
fixtures. Thereafter, the revolution counter on the measuring board is set to zero and the
resolver angle is read for each axis to be calibrated.
11.2.2 Calibrating the Robot

All robots are calibrated before shipped to the end user, and the calibration values are
written on a resolver offset label.
Situations may however occur which will cause the robot to need re-calibration. These
situations may be:
– The robot axes have been moved with the control system not operative.
– The backup batteries have been discharged, e.g. as a result of the robot being switched
off for an extended period of time.
– The signal between the resolver and the measurement board has been interrupted.
– Mains power has failed while the robot was moving rapidly.
– Extensive oscillations in an axis.
– Service work has been performed on the robot which has affected the axis / resolver
relationship.
Information on how to calibrate one, more or all of the robot axes is found in
’Calibrating the Robot’ on page 176. Calibration fixtures are required to perform this
operation.
11.2.3 Update Revolution Counter

A special situation may occur when only the information in the revolution counter is lost.
The robots axes can then be updated by placing the robot in an approximate calibration
position and then updating the counters from the teach pendant.
Note. This function can not be used for the hollow wrist as the wrist axes on the hollow
wrist has endless rotation, and calibration using the calibration fixture is always
necessary unless in situations where it is 100% certain that the axes are within correct
revolution, i.e. the same revolution as they were calibrated.
Situations where only the revolution counter is lost may be:

– The backup battery for the revolution counter has been discharged, e.g. as a result of
the robot being switched off for an extended period of time.
– Connection between measuring board and motor has been disconnected.
Information on how to update the revolution counter is found in ’Updating Revolution
Counters’ on page 178.
11.2.4 Check Calibration Position

The calibration position can be checked by running special service program or by
jogging the robot to calibration marks and check calibration values. Information on how
to check the calibration is found in ’Check Calibration Position’ on page 180.
11.2.5 Resolver Offset Label
Figure 95 Label for calibration values
RESOLVER OFFSET
(WRITE IN PENCIL)
AXIS
SYNCHRONOUS
POSITION
1
2
3
4
5
6
7
When the robot is calibrated before shipment, the calibration values are written in a label
located inside a panel on the robot, shown in the calibration fixture installation drawing.
The values will apply unless a component affecting the calibration of the robot etc. has
been replaced.
If you need to calibrate the robot and no components have been replaced, you can just
enter the calibration values from the label.
If a component has been replaced and new calibration using the calibration fixture has
been performed, the information in the Resolver Offset label should be updated.
For location of the label on the robot, please refer to the illustration showing the
calibration fixture installation found in chapter ‘Calibration Fixture Installation’ in this
manual.

11.3 Calibrating the Robot

This procedure gives information for calibrating the robot. The calibration fixture is
required when performing this operation.
The axes are calibrated in numerical order; 1, 2, 3, 4, 5, 6.
WARNING!
Read ’Safety Precautions’ on page 173 before continuing.
1. Press the Misc key on the teach pendant.
2. Choose Service from the dialog box which appears on the display.
3. Press the Enter key .
4. Choose View: Calibration. The window shown in figure 96 will appear.
Figure 96 The window shows whether or not the robot needs calibration
File Edit View Calib

Service Calibration
Mech Unit Status

====================================1(4)
IRB Not Calibrated
The calibration status can be any of the following:

Synchronized (Calibrated). All axes are calibrated and their positions are known to
the control system. The robot is ready for operation.
Not updated Rev. Counter. All axes are calibrated, but the revolution counter for
one or more of the axes is NOT updated. This only applies to the main axes (axis
1,2,3). The wrist axes must be calibrated (not update revolution counter) unless it is
absolutely certain that the wrist axes are in the revolution in which they were
calibrated.
Not calibrated. One or more of the axes is NOT calibrated. The axis or axes must
therefore be calibrated as described in the following.
5. Install calibration fixture as described in chapter ‘Calibration Fixture Installation’ in
this manual.
6. When calibration fixture has been installed, choose Calib: Calibrate. The window
shown in figure 97 will appear.

Figure 97 The dialog box used to calibrate the manipulator
Calibration!
Robot
To calibrate, include axes and press OK.
Axis Status
====================================1(6)
x 1 Not Calibrated
x 2 Not Calibrated
3 Calibrated
4 Calibrated
x 5 Not Calibrated
x 6 Not Calibrated
Incl All Cancel OK
7. Press the function key All if all axes are to be calibrated or select the required axis /
axes and press the function key Incl. The selected axis / axes will be marked with
an x.
8. Confirm your choice by pressing the function key OK. The window shown in
figure 98 will appear.
Figure 98 The dialog box used to start the calibration
Calibration!
IRB
The calibration for all marked axes

will be changed.
It cannot be undone.
OK to continue?
Cancel OK
9. Start the calibration by pressing OK.

An alert box will be displayed during the calibration. The status window will appear
when the calibration is completed. The revolution counters are always updated as the
calibration is performed.
10. Repeat operation if more axes are to be calibrated.
11. Remove calibration fixture.
12. Check calibration as described in ’Check Calibration Position’ on page 180.
13. Save parameters as described in User’s Guide under System Parameters.

11.4 Updating Revolution Counters

When starting up a new robot, a message may be displayed telling you that the robot is
not synchronized. The message appears in form of an error message on the teach
pendant. If you receive such a message, the revolution counter of the manipulator must
be updated using the calibration marks on the manipulator.
IMPORTANT: Only the revolution counters for axis 1, 2 end 3 can be updated as
described in this procedure. Axes 4, 5, 6 of the hollow wrist has endless rotation and
calibration is required unless it can be stated with absolute certainty that the axes are
within correct revolution, i.e. the same revolution as they were calibrated.
If you are not sure that the wrist is in correct revolution and want to avoid a new
calibration, you can try to update the revolution counter as described in the procedure
below. After the procedure has been performed (the revolution counter has been
updated), you MUST verify the result by running a RAPID program containing a
MoveAbsJ statement which will move the wrist into calibration position and then check
that the calibration marks on the wrist meet.
WARNING!
Read ’Safety Precautions’ on page 173 before continuing.
1. Press the Misc key on the teach pendant.
2. Choose Service from the dialog box which appears on the display.
3. Press the Enter key .
4. Choose View: Calibration. The window shown in figure 99 will appear.
Figure 99 The window shows whether or not the robot needs calibration
File Edit View Calib

Service Calibration
Mech Unit Status

====================================1(4)
IRB Unsynchronized
5. Select Unit: IRB + .

6. Place the robot in calibration position as described in chapter ‘Calibration Fixture
Installation’ in this manual.
7. Choose Calib: Rev. Counter Update. The window shown in figure 100 will appear.

Figure 100 The dialog box used to start the calibration
Rev. Counter Updating!

IRB
TO update, include axes and press OK.
Axis Status
====================================1(6)
x 1 Not updated Rev. Counter
3 Calibrated
4 Calibrated
Incl All Cancel OK
8. Select the required axis / axes for which the revolution counter is to be updated.
Press the function key Incl. The selected axis / axes will be marked with an x.
9. Confirm selection by pressing OK. A window similar to the window shown in
figure 101 will appear.
Figure 101 The dialog box used to start updating the revolution counter
Rev. Counter Updating!

IRB
The Rev. Counter for all marked axes

will be changed.
It cannot be undone.
OK to continue?
Cancel OK
10. Start update revolution counter by pressing OK.
WARNING!
If a revolution counter is incorrectly updated, it will cause incorrect positioning of
the manipulator axes. For this reason, check the calibration carefully after each
update. Incorrect updating can cause personnel injury or serious damage to the
robot.
11. Check calibration as described in ’Check Calibration Position’ on page 180.

11.5 Check Calibration Position

There are two ways to check the calibration position:
Note. For location of calibration marks and calibration position values, see chapter
‘Calibration Fixture Installation’ in this manual.
Using the Robot Utility Program:

Run the robot into calibration position by means of the program Main_Nofac, found on
the CD-ROM under the folder ‘Standard Tools’ (for old cabinet on the ‘Utility Program’
diskette). When the robot is in the calibration position, switch to MOTORS OFF. Check
that the calibration marks for each axis are on the same level. If they are not, the
calibration must be repeated.
Using the Jogging Window on the Teach Pendant:

Open the Jogging window and choose running axis-by-axis. Using the joystick,
move the robot so that the read-out of the positions is correct. Check that the calibration
marks for each axis are on the same level. If they are not, the calibration must be
repeated.

Calibration Fixture Installation
12 Calibration Fixture Installation

This chapter provides instructions for installation of the calibration fixture for the robot.
The illustration for calibration fixture installation also includes information on location
of calibration marks, location of resolver offset label and calibration position values.

12.1 Calibration Fixture Installation, Axes 1,2,3

Following procedure describes how to install the calibration fixture for the main axes.
Figure 102 Calibration fixture installation, main axes
5 Resolver offset label

(inside cover)
Calibration
marks, Axis 3 Axis 2 fixture 8
6
9
10
7
Located on Axis 3 fixture
Calibration inner surface
marks, Axis 2
(Old style)
Calibration
marks, Axis 1
2 1 1 3
Calibration
position, Axis 1
Calibration
marks, Axis 2
2 4 (New style)
Axis 1 fixture
Calibration Position Values

Axis 1 Axis 2 Axis 3 Axis 7 *1
40° 0° 60° 0°
*1 Axis 7 applies for trolley version
IMPORTANT: Read ’Safety Precautions’ on page 173 before continuing.

1. Release the axis brakes, see ’Releasing Axis Brakes’ on page 11. Then install
calibration fixture for the required main axes as follows.
2. Rotate axis 1 to a position where the two studs (102/1) on the foot unit and the stud
(102/2) on the rotating unit are lined up as shown in figure 102.
3. Install the calibration fixture (102/3) across the studs and tighten screw (102/4).
4. Remove protective screw from alignment hole (102/5) on vertical arm.

5. Move axis 2 (vertical arm) to the position shown in figure 102 and install the
calibration fixture (102/6) between base alignment stud (102/7) and vertical arm
alignment hole (102/5).
6. Remove protective screw from alignment hole (102/8) on vertical arm and alignment
hole (102/10) on horizontal arm.
7. Move axis 3 (horizontal arm) to the position shown in figure 102 and install the
calibration fixture (102/9) between alignment holes on the vertical and horizontal
arm.
8. Activate brakes.
NOTE: After the calibration is completed, remove calibration fixture for axis 1, 2
and 3, and install protective screws.
9. Return to procedure ’Calibrating the Robot’ on page 176, continuing from step 6. to
complete the calibration.

12.2 Calibration Fixture Installation, Hollow Wrist

Following procedure describes how to install the calibration fixture for the hollow wrist
axes.
Figure 103 Calibration position for axes 4-6

5 3 7 4 Axis 4 6 Calibration mark
axis 6
Calibration mark
axis 4
Calibration mark
axis 5 8 2 Axis 5 Axis 6 1
Calibration Position Values
Axis 4 Axis 5 Axis 6
0° 0° 0°
IMPORTANT: Read ’Safety Precautions’ on page 173 before continuing.

1. Release the axis brakes, see ’Releasing Axis Brakes’ on page 11, and rotate axis 4, 5
and 6 to the position shown in figure 103.
2. Align axis 6 notch (103/1) and axis 5 studs (103/2) horizontally and axis 4 pin
(103/3) upwards.
Note: When aligning axis 6, check that the axis is in the correct revolution as hoses
are concerned. This can be found by looking or feeling that the hoses at the outlet in
the rear end of the arm are not twisted or strained.
3. Install rear fixture section (103/4). Align fixture guide pins (103/8) on axis 5 studs
(103/2) and top slot on axis 4 guide pin (103/3). Install screws (103/5) on both sides
of arm to lock axis 4 in a fixed position.
4. Install front fixture section (103/6) while checking that alignment notches (103/1)
are properly engaged. Tighten screw (103/7) to lock axis 5 and 6 in a fixed position.
5. Activate brakes.
Note: After the calibration is completed, remove calibration fixture.
6. Return to procedure ’Calibrating the Robot’ on page 176, continuing from step 6. to
complete the calibration.

Reference Drawings
13 Reference Drawings
figure 104 - Location of components
figure 105 - Manipulator base, right side- and rear view
figure 106 - Vertical arm, side- and rear view

Reference Drawings
Figure 104 Location of components

Horizontal arm
H40 Horizontal arm
1
H10 Horizontal arm
2 Wrist
6 7
Upper bevel gear
3
14
Vertical arm
4
Lower bevel gear
5 Axis 3 15
Axis 1
Base unit 16
8 Foot unit
Manipulator - Right side view
H40 Horizontal arm
H10 Horizontal arm
13
9
10
11
5
15 Axis 2
11
16 12
Base unit rear view
Manipulator - Left side view

Reference Drawings
Figure 105 Manipulator base, right side- and rear view
19
20
21
4
1 5
2 6
7
8
9
10
3
11
12
13
7 8
14 15
16
17
18

Reference Drawings
Figure 106 Vertical arm, side- and rear view
2
3 8
4
9
5
10
6
11
15
7 16
12
17
13
14

Manual Identification File
Manual Status
Service Manual
IRB 5400-02
3HNT 02330-1 en Rev.03
Documents included in manual:
Sec.: Subject: File Identification Page:

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02277 Rev.02 7
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02102 Rev.04 13
3 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . T02519 Rev.01 19
4 Base unit guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T00127 Rev.12 29
5 Vertical arm guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . T00127A Rev.01 67
6 H10 Horizontal arm guidelines. . . . . . . . . . . . . . . . . . . . . . T00129 Rev.10 87
7 H40 horizontal arm guidelines . . . . . . . . . . . . . . . . . . . . . . T00725 Rev.07 107
8 Hollow wrist unit guidelines. . . . . . . . . . . . . . . . . . . . . . . . T00520 Rev.04 135
9 Oil change in gear boxes . . . . . . . . . . . . . . . . . . . . . . . . . . T00131 Rev.09 147
10 Replacing cable units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T00127B Rev.02 153
11 Calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02096 Rev.01 173
12 Calibration fixture installation . . . . . . . . . . . . . . . . . . . . . . T00514 Rev.09 181
13 Reference drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T00132 Rev.10 185
BOOKLOM.fm 3HNT 02330-1 en Rev.03 Page 189

Page 190 3HNT 02330-1 en Rev.03 BOOKLOM.fm
List of Imported Graphics

Service Manual
IRB 5400-02
3HNT 02330-1 en Rev.03
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Page: Illustration: Page: Illustration: Page: Illustration:

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Service Manual

Publ.No.: 3HNT 02330-1 en Rev.03

ABB AS, Robotics

© 2004-2006 ABB AS, Robotics

ABB AS, Robotics

First Edition: 10 June 2004

4 Base Unit Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3HNT 02330-1 en Rev.03 3

5 Vertical Arm Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6 H10 Horizontal Arm Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7 H40 Horizontal Arm Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

8 Hollow Wrist Unit Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

9 Oil Change in Gear Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

4 3HNT 02330-1 en Rev.03

10 Replacing Cable Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

11 Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

12 Calibration Fixture Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

13 Reference Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

3HNT 02330-1 en Rev.03 5

1.1 Safety Guidelines

Service Manual 3HNT 02330-1 en Rev.03 7

1.2 Description of Publication

1.3 General Information

8 3HNT 02330-1 en Rev.03 Service Manual

1.5 Motor Units

Service Manual 3HNT 02330-1 en Rev.03 9

1.6 Component Overview

Figure 1 Component identification

Horizontal arm, H40 (process arm)

Upper bevel gear

Horizontal arm, H10

Vertical arm, V11 Vertical arm, V12

Lower bevel gear

Riser foot unit

10 3HNT 02330-1 en Rev.03 Service Manual

1.7 Releasing Axis Brakes

Figure 2 Brake release connections on motor connectors

Service Manual 3HNT 02330-1 en Rev.03 11

1.8 Special Tools

Guiding Bolt Tool

Rotor Rotating Tool

Calibration Fixture Kit

Valve and Spring Cover Pin Wrench

Purge System Bypass Switch (Purge Link)

Cable RS422 CNV Debug PC

12 3HNT 02330-1 en Rev.03 Service Manual

2.1 Mounting Instructions for Bearings

2.1.2 Tapered Bearings

2.1.3 Greasing Bearings

Service Manual 3HNT 02330-1 en Rev.03 13

2.2 Mounting Instructions for Seals

2.2.2 Rotating Seals

2.2.3 Flange Seals and Static Seals

14 3HNT 02330-1 en Rev.03 Service Manual

Service Manual 3HNT 02330-1 en Rev.03 15

2.3 Instructions for Tightening Screw Joints

2.3.2 Tightening Torques

Table 2 Torque table, screws with slotted or cross recessed head

2.3.3 Using Loctite