Page 1 Product manual Articulated robot IRB 4400 - 45 IRB 4400 - 60 IRB 4400 - L10 IRB 4400 - L30 IRB 4400 - LS IRB 4400 - 45 M2000, M2000A, M2004...
Page 3 Product manual IRB 4400 - 45 IRB 4400 - 60 IRB 4400 - L10 IRB 4400 - L30 IRB 4400 - S IRB 4450S M2000 M2004 Document ID: 3HAC022032-001 Revision: E...
Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Table of Contents Overview ................7 Product documentation, M2000/M2000A .
Page 6 Table of Contents 2.5 Electrical connections ............. . 77 2.5.1 Customer connection on robot .
Page 7 Table of Contents 4.6.4 Replacement of mechanical stop pin, axis 1 ........186 4.7 Motors .
Page 8 Table of Contents 3HAC022032-001 Revision: E...
Page 9: Overview
Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters:...
Page 10 Overview Continued Revisions Revision Description First edition. Replaces previous manuals: • Installation and Commissioning Manual • Maintenance Manual • Repair Manual, part 1 • Repair Manual, part 2. Changes made in the material from the previous manuals: • Model M2004 implemented. Chapter Safety, service replaced with chapter Safety.
Page 11: Product Documentation, M2000/M2000A
A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation. Each document set contains the types of information specified below: •...
Page 12: Product Documentation, M2004
This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems.
Page 13 Product documentation, M2004 Continued Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: • The purpose of the application (what it does and when it is useful) •...
Page 14: How To Read The Product Manual
How to read the product manual How to read the product manual Reading the procedures The procedures contain references to figures, tools, material etc. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the robot/controller.
Page 15: Safety
1 Safety 1.1. Introduction 1 Safety 1.1. Introduction Overview The safety information in this manual is divided in two categories: • general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in section General safety information on page •...
Page 16: General Safety Information
Limitation of liability Any information given in this manual regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. Related information...
Page 17: Safety Risks
Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
Page 18 1 Safety 1.2.2.1. Safety risks during installation and service work on robot Continued Complete robot Safety risk Description Hot components! Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Removed parts may result in collapse of robot! Take any necessary measures to ensure that the robot does not collapse as parts are removed, e.g.
Page 19: Safety Risks Related To Tools/Workpieces
1 Safety 1.2.2.2. Safety risks related to tools/workpieces 1.2.2.2. Safety risks related to tools/workpieces Safe handling It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves).
Page 20: Safety Risks Related To Pneumatic/Hydraulic Systems
1 Safety 1.2.2.3. Safety risks related to pneumatic/hydraulic systems 1.2.2.3. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy may be present in these systems. After shutdown, particular care must be taken.
Page 21: Safety Risks During Operational Disturbances
1 Safety 1.2.2.4. Safety risks during operational disturbances 1.2.2.4. Safety risks during operational disturbances General • The industrial robot is a flexible tool which can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.
Page 22: Risks Associated With Live Electric Parts
1 Safety 1.2.2.5. Risks associated with live electric parts 1.2.2.5. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.
Page 23 1 Safety 1.2.2.5. Risks associated with live electric parts Continued Voltage related risks, IRC5 controller A danger of high voltage is associated with for example the following parts: • Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.
Page 24: Safety Actions
1 Safety 1.2.3.1. Safety fence dimensions 1.2.3. Safety actions 1.2.3.1. Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.
Page 25: Fire Extinguishing
1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot system (manipulator or controller)! 3HAC022032-001 Revision: E...
Page 26: Emergency Release Of The Robot's Arm
1 Safety 1.2.3.3. Emergency release of the robot’s arm 1.2.3.3. Emergency release of the robot’s arm Description In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot. How to release the brakes is detailed in section: •...
Page 27: Brake Testing
1 Safety 1.2.3.4. Brake testing 1.2.3.4. Brake testing When to test During operation the holding brake of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function. How to test The function of the holding brake of each axis motor may be checked as detailed below: 1.
Page 28: Risk Of Disabling Function "Reduced Speed 250 Mm/S
1 Safety 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" Do not change "Transm gear ratio" or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC022032-001 Revision: E...
Page 29: Safe Use Of The Flexpendant
1 Safety 1.2.3.6. Safe use of the FlexPendant 1.2.3.6. Safe use of the FlexPendant The enabling device is a push button located on the side of the FlexPendant which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
Page 30: Work Inside The Manipulator's Working Range
1 Safety 1.2.3.7. Work inside the manipulator's working range 1.2.3.7. Work inside the manipulator's working range If work must be carried out within the robot’s work envelope, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.
Page 31: Translate The Information On Safety And Information Labels
Using a transparent sticker over the standard label with text added in a fourth language. Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.
Page 32: Safety Related Instructions
1 Safety 1.3.1. Safety signals, general 1.3 Safety related instructions 1.3.1. Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: •...
Page 33 1 Safety 1.3.1. Safety signals, general Continued Symbol Designation Signification ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Electrostatic discharge (ESD) NOTE Note symbols alert you to important facts and conditions.
Page 34: Danger - Moving Manipulators Are Potentially Lethal
1 Safety 1.3.2. DANGER - Moving manipulators are potentially lethal! 1.3.2. DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running the manipulator, it may perform unexpected and sometimes irrational movements. However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the manipulator working range.
Page 35: Danger - First Test Run May Cause Injury Or Damage
1 Safety 1.3.3. DANGER - First test run may cause injury or damage! 1.3.3. DANGER - First test run may cause injury or damage! Description Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run. Elimination Follow the procedure below when performing the first test run after a service activity (repair, installation or maintenance):...
Page 36: Warning - The Unit Is Sensitive To Esd
1 Safety 1.3.4. WARNING - The unit is sensitive to ESD! 1.3.4. WARNING - The unit is sensitive to ESD! Description ESD (electro static discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges.
Page 37 1 Safety 1.3.4. WARNING - The unit is sensitive to ESD! Continued Assemble the wrist strap The picture illustrates how the ESD wrist strap is assembled in the controller. xx0400001055 The strap is fastened to a button on the side of the control module. When not used, the wrist strap is placed on the power supply unit.
Page 38: Warning - Safety Risks During Work With Gearbox Oil
1 Safety 1.3.5. WARNING - Safety risks during work with gearbox oil 1.3.5. WARNING - Safety risks during work with gearbox oil Description When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes! Warnings and elimination Warning...
Page 39: Installation And Commissioning
2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot to the working site. More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), may be found in the Product Specification for the robot. 3HAC022032-001 Revision: E...
Page 40: Unpacking
2 Installation and commissioning 2.2.1. Pre-installation procedure 2.2 Unpacking 2.2.1. Pre-installation procedure General These instructions are to be used when unpacking and installing the robot for the first time. They also contain information useful later during re-installation of the robot. Checking the pre-requisites for installation The check-list below details what must be observed before proceeding with the actual installation of the robot:...
Page 41 2 Installation and commissioning 2.2.1. Pre-installation procedure Continued Loads on foundation, robot - all versions except IRB 4400/S and 4450S The table below shows the various forces and torques working on the robot during different kinds of operation. Stress forces for the robot versions IRB 4400/S and IRB 4450S are detailed separately in the following tables.
Page 42 2 Installation and commissioning 2.2.1. Pre-installation procedure Continued Loads on foundation, robot version IRB 4450S The illustration below shows the directions of the stress forces. xx0500002108 This table shows stress forces for the robot version IRB 4450S. Force Endurance load (in operation) Max. load (emergency load) Force xy ±7500 N ±10000 N...
Page 43 2 Installation and commissioning 2.2.1. Pre-installation procedure Continued This table shows stress forces for the robot version IRB 4400/S. Force Endurance load (in operation) Max. load (emergency stop) Force x ± 5000 N ± 7000 N Force y ± 6000 ±...
Page 44: Working Range, Irb 4400/45 And /60
2 Installation and commissioning 2.2.2. Working range, IRB 4400/45 and /60 2.2.2. Working range, IRB 4400/45 and /60 Extreme positions The illustration below shows the extreme positions of the robot arms IRB 4400/45 and /60: xx0300000241 Position X Position Z Angle Axis 2 Angle Axis 3 Pos no.
Page 45: Working Range, Irb 4400/L30
2 Installation and commissioning 2.2.3. Working range, IRB 4400/L30 2.2.3. Working range, IRB 4400/L30 Extreme positions The illustration below shows the extreme positions of the robot arm IRB 4400/L30: xx0300000242 Positions in Position X Position Z Angle Axis 2 Angle Axis 3 illustration (mm) (mm)
Page 46: Working Range, Irb 4400/L10
2 Installation and commissioning 2.2.4. Working range, IRB 4400/L10 2.2.4. Working range, IRB 4400/L10 Extreme positions The illustration below shows the extreme positions of the robot arm IRB 4400/L10: xx0300000244 Position in Position X Position Z Angle Axis 2 Angle Axis 3 illustration (mm) (mm)
Page 47: Working Range, Irb 4400/S
2 Installation and commissioning 2.2.5. Working range, IRB 4400/S 2.2.5. Working range, IRB 4400/S Extreme positions The illustration below shows the extreme positions of the robot arm IRB 4400/S: xx0300000243 Positions in Position X Position Z Angle Axis 2 Angle Axis 3 illustration (mm) (mm)
Page 48: Working Range, Irb 4450S
2 Installation and commissioning 2.2.6. Working range, IRB 4450S 2.2.6. Working range, IRB 4450S Extreme positions The illustration below shows the extreme positions of the robot arm IRB 4450S: 1176 2400 xx0500002034 Positions in Position X Position Z Angle Axis 2 Angle Axis 3 illustration (mm)
Page 49: Risk Of Tipping/Stability - Irb 4450S
2 Installation and commissioning 2.2.7. Risk of tipping/stability - IRB 4450S 2.2.7. Risk of tipping/stability - IRB 4450S Risk of tipping When the robot model IRB 4450S not is fastened to the foundation and standing still, the robot is not stable in the whole working area. Moving the arms will displace the center of gravity, which may cause the robot to tip over.
Page 50: On-Site Installation
2 Installation and commissioning 2.3.1. Lifting robot with round slings 2.3 On-site installation 2.3.1. Lifting robot with round slings General Lift the robot using lifting straps and a traverse crane according to this section. The instructions are separated for the robot versions IRB 4400/45, /60, /L10, /L30 and for robot versions IRB 4400/S and 4450S.
Page 51 2 Installation and commissioning 2.3.1. Lifting robot with round slings Continued Lifting, robot version IRB 4400/45, /60, /L10, /L30 The lifting equipment is attached to the robot as shown in the figure below. xx0300000245 Angle (degrees specified for the different versions in the lifting instruction) Lifting lug Lifting instruction, IRB 4400/45, /60, /L10, /L30 The procedure below details how to lift the complete robot (IRB 4400/45, /60, /L10, /L30).
Page 52 2 Installation and commissioning 2.3.1. Lifting robot with round slings Continued Action Info/Illustration 4. Attach the round slings to the special eye bolts on the Shown in the figure Lifting, gearbox unit for axes 2 and 3 using lifting lugs. robot version IRB 4400/45, / 60, /L10, /L30 on page The roundsling and lifting lug...
Page 53 2 Installation and commissioning 2.3.1. Lifting robot with round slings Continued Lifting instruction, IRB 4400/S The procedure below details how to lift the complete robot (IRB 4400/S). Action Note/Illustration 1. Release the brakes manually, to make it possible to Detailed in section Manually alter the positions of the arms.
Page 54 2 Installation and commissioning 2.3.1. Lifting robot with round slings Continued Lifting robot version IRB 4450S The lifting equipment is attached to the robot as shown in the figure below. xx0500002035 Angle (degrees specified for the different versions in the lifting instruction) Mechanical stop Lifting instruction, IRB4450S The procedure below details how to lift the complete robot (IRB 4450S)
Page 55 2 Installation and commissioning 2.3.1. Lifting robot with round slings Continued Action Info/Illustration 5. Attach the round slings to the special eye bolts on the Attachment points are gearbox unit for axes 2 and 3 using lifting lugs. Also shown in figure attach the round slings around the mechanical stop xx0500002035 above.
Page 56: Manually Releasing The Brakes
2 Installation and commissioning 2.3.2. Manually releasing the brakes 2.3.2. Manually releasing the brakes General The section below details how to release the holding brakes of each axis' motor. This may be done in one of three ways: • using the pushbutton when the robot is connected to the controller. •...
Page 57 2 Installation and commissioning 2.3.2. Manually releasing the brakes Continued Action Info/Illustration 2. Release the holding brake on a particular axis by pressing the corresponding button on the pushbutton unit and keeping it depressed. The brake will function again as soon as the button is released.
Page 58 2 Installation and commissioning 2.3.2. Manually releasing the brakes Continued Using an external voltage supply directly on the respective brake The procedure below details how to release the holding brake of a specific axis by supplying external voltage directly on the brake. Action Note/Illustration 1.
Page 59: Orienting And Securing The Robot
2 Installation and commissioning 2.3.3. Orienting and securing the robot 2.3.3. Orienting and securing the robot General This section details how to orient and secure the robot to the base plate after fitting it to the foundation. Securing parts/facts The table below specifies the type of securing screws and washers to be used to secure the robot to the base plate/foundation.
Page 60 2 Installation and commissioning 2.3.3. Orienting and securing the robot Continued Hole configuration and dimensions The illustration below shows the hole configuration and hole dimensions of the robot base, seen from below. The cut x-x shows the dimension of the rear bolt holes, where the guide sleeves may be used. xx0300000252 Rear bolt holes Center line, axis 1...
Page 61 2 Installation and commissioning 2.3.3. Orienting and securing the robot Continued Action Info/Illustration 6. Fit the securing screws and washers in the base Specified in Securing parts/ attachment holes. facts on page Attachment holes shown in the figure Hole configuration and dimensions on page 7.
Page 62: Fitting Equipment On Robot
Make sure the required mounting holes are accessible when planning the robot cell. Never drill a hole in the robot without first consulting ABB! Fitting equipment on upper arm, IRB 4400/45, /60, /L30, /S and IRB 4450S The illustration below shows the mounting holes available for fitting extra equipment on the upper arm for robot versions IRB 4400/45, /60, /L30, /S and IRB 4450S.
Page 63 2 Installation and commissioning 2.3.4. Fitting equipment on robot Continued Fitting equipment on upper arm, IRB 4400/L10 The illustration below shows the mounting holes available for fitting extra equipment on the upper arm for robot versions IRB 4400/L10. The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes.
Page 64 2 Installation and commissioning 2.3.4. Fitting equipment on robot Continued Fitting equipment on gearbox unit, IRB 4400/45, /60, /L10, /L30 and IRB 4400/S The illustration below shows the mounting holes available for fitting extra equipment on the gearbox unit. The shaded area indicates the permitted positions (center of gravity) for any extra equipment mounted in the holes.
Page 65 2 Installation and commissioning 2.3.4. Fitting equipment on robot Continued Fitting equipment on mounting flange, IRB 4400/45, /60, /L30, /S and IRB 4450S The illustration below shows the mechanical interface for the mounting flange, robot version IRB 4400/45, /60, /L30, /S and IRB 4450S. xx0300000267 Fitting equipment on mounting flange, IRB 4400/10 The illustration below shows the mechanical interface for the mounting flange, robot version...
Page 66: Loads
Specification. The loads must also be defined in the software as detailed in User's Guide(RobotWare 4.0)Operating manual(RobotWare 5.0). Stop time and braking distances Robot motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. 3HAC022032-001 Revision: E...
Page 67: Restricting The Working Range
2 Installation and commissioning 2.4.1. Introduction 2.4 Restricting the working range 2.4.1. Introduction General When installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. The working range of the following axes may be restricted: •...
Page 68: Mechanically Restricting The Working Range Of Axis 1
2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 2.4.2. Mechanically restricting the working range of axis 1 Mechanically restricting the working range The working range of axis 1 can be restricted mechanically by fitting additional mechanical stops to the base, as detailed in this section.
Page 69 2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 Continued Additional stops The additional stops are fitted as shown in the figure below. xx0300000258 Mechanical stop lugs Attachment screw and washer Stop pin Max. working range with stop lugs (250°) Min.
Page 70 2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 Continued Fitting, mechancial stop axis 1 The procedure below details how to fit the additional mechanical stop to the base. Mounting instructions are also supplied with the kit. Action Info/Illustration 1.
Page 71: Mechanically Restricting The Working Range Of Axis 2
2 Installation and commissioning 2.4.3. Mechanically restricting the working range of axis 2 2.4.3. Mechanically restricting the working range of axis 2 Mechanically restricting the working range The working range of axis 2 can be restricted mechanically by fitting additional mechanical stops (spacers and dampers) to the lower arm and gearbox unit axis 1-3, as detailed in this section.
Page 72 2 Installation and commissioning 2.4.3. Mechanically restricting the working range of axis 2 Continued Additional stops The additional mechanical stops (spacers and dampers) are fitted to the lower arm and the gearbox unit, as shown in the figure below. xx0300000260 View A of the lower arm View B of the lower arm Cut of the mech stop attachment...
Page 73 2 Installation and commissioning 2.4.3. Mechanically restricting the working range of axis 2 Continued Damper Attachment screw, damper (+nut) Working ranges The working range of axis 2 can be restricted according to the table below. The table applies to all robot versions except IRB 4400/FS. Note! Initial position for the IRB 4450S is +48°...
Page 74 2 Installation and commissioning 2.4.3. Mechanically restricting the working range of axis 2 Continued Action Info/Illustration 3. Fit the dampers to both sides of the lower arm with the Shown in the figure attachment screws and nuts, damper. Additional stops on page Art.
Page 75: Electrically Restricting The Working Range Of Axis 3
2 Installation and commissioning 2.4.4. Electrically restricting the working range of axis 3 2.4.4. Electrically restricting the working range of axis 3 Electrically restricting the working range The working range of axis 3 can be limited by fitting an electric switch on the gearbox for axis 3, which senses the current position via a cam.
Page 76 2 Installation and commissioning 2.4.4. Electrically restricting the working range of axis 3 Continued Required equipment Spare part Equipment, etc. Art. no. Note Electrical stop, axis 3 3HAB 3795-1 Includes all spare parts shown in the figure Electrical stop on page Locking liquid Loctite 243...
Page 77: Unlimited Working Range
2 Installation and commissioning 2.4.5. Unlimited working range 2.4.5. Unlimited working range Resetting the work area for an axis The function "Resetting the work area for an axis", included in Advanced Motions 3.0, can also be used for axis 4. To enable this function, the mechanical stop on axis 4 should be removed.
Page 78 2 Installation and commissioning 2.4.5. Unlimited working range Continued Removal of mechanical stop, axis 4 The procedure below details how to remove the mechanical stop of axis 4, to enable the function "Resetting the work area for an axis". When the damper is removed from axis 4, the axis does not have a mechanical stop! If the robot is provided with cabling on the upper arm, the cabling can be damaged when the function “Resetting the work area for an axis”...
Page 79: Electrical Connections
2 Installation and commissioning 2.5.1. Customer connection on robot 2.5 Electrical connections 2.5.1. Customer connection on robot General For connection of extra equipment to the robot, cables and air hose are integrated into the robot´s cabling, and there is one FCI UT071823SH44N and one FCI UT071412SH44N connector on the rear part of the upper arm.
Page 80 2 Installation and commissioning 2.5.1. Customer connection on robot Continued Connection sets To connect power and signal conductors to the robot base/upper arm connectors, the following parts are recommended. Connection set Connector Art. no. Content Connection set R1.CP/CS 3HAC 12275-1 •...
Page 81: Customer Connections On Upper Arm
2 Installation and commissioning 2.5.2. Customer connections on upper arm 2.5.2. Customer connections on upper arm Customer connection on upper arm The figure below shows the customer connections on the upper arm, including the optional signal lamp that can be fitted to the rear of the arm. xx0300000269 R2.CP R2.CS...
Page 82 2 Installation and commissioning 2.5.2. Customer connections on upper arm Continued Customer Contact on robot Customer Customer base Signal name Terminal Contact on (cable between robot and con- Controller Upper arm, R2 troller not supplied) XT6.8 R2.CP.K RI.CP/CS.D2 XT6.9 R2.CP.L RI.CP/CS.A3 XT6.10 R2.CP.M...
Page 83: Additional Installation (Foundry Prime)
Environmental conditions Humidity 100% Washing detergent with pH <9.0 Washing detergent must be approved by ABB. Cleaning bath temperature <60°C, used in a typical waterjet cleaning application at suitable speed. Air specification for pressurizing of robot The air must be dry and clean, such as instrument air.
Page 84 2 Installation and commissioning 2.6.1. Installation of IRB4400 in a water jet application Continued Pressurize the motors and serial measurement board cavity The robots are prepared with hoses to the motors and the serial measurement board cavity to enable pressurizing of them. The robot must be pressurized also when it is switch off, to avoid that the humid environmental air is sucked into the motors when cooling down.
Page 85 2 Installation and commissioning 2.6.1. Installation of IRB4400 in a water jet application Continued xx0600003108 Axis 5, bearing support side Axis 5, bearing gear side Axis 6, mounting flange - gear house Protecting the wrist flange from corrosion The mounting surface on the wrist flange is protected with grease. The joint between the wrist flange and the tool and the screw holes on the wrist flange should be protected.
Page 86: Commissioning (Foundry Prime)
2 Installation and commissioning 2.6.2. Commissioning (Foundry Prime) 2.6.2. Commissioning (Foundry Prime) General The following shouold be taken in consideration when running a robot in a water jaet application cell. Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off.
Page 87: Making Robot Ready For Operation (Cleanroom)
2 Installation and commissioning 2.7.1. Additional installation procedure. 2.7 Making robot ready for operation (Cleanroom) 2.7.1. Additional installation procedure. General Cleanroom robots are specially designed to work in a cleanroom environment. Cleanroom robots are designed in order to prevent from particle emission from the robot. For example some articles in the robot's design, which normally are exposed to some wear during operation, are unpainted.
Page 88 2 Installation and commissioning 2.7.1. Additional installation procedure. 3HAC022032-001 Revision: E...
Page 89: Maintenance
3 Maintenance 3.1. Introduction 3 Maintenance 3.1. Introduction Structure of this chapter This chapter details all maintenance activities recommended for the robot and any external units of the robot. It is based on the maintenance schedule, located in the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.
Page 90: Maintenance Schedule
3 Maintenance 3.2.1. Specification of maintenance intervals 3.2 Maintenance schedule 3.2.1. Specification of maintenance intervals Description The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot: •...
Page 91: Maintenance Schedule
3 Maintenance 3.2.2. Maintenance schedule 3.2.2. Maintenance schedule General The robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately! The inspection intervals do not specify the life of each component.
Page 92 3 Maintenance 3.2.2. Maintenance schedule Continued Activities and intervals (Foundry Prime application) Robots working with water jet cleaning and that have the special tightness for this application require special maintenance for proper function. The maintenance must be done according to the maintenance schedule in the Product Manual and the following additional maintenance.
Page 93: General Maintenance Activities
3 Maintenance 3.3.1. Inspection of mechanical stop, axis 1 3.3 General maintenance activities 3.3.1. Inspection of mechanical stop, axis 1 Location of mechanical stop The mechanical stop on axis 1 is located on the frame as shown in the figure below. xx0300000182 Mechanical stop pin, axis 1 Set screw...
Page 94 3 Maintenance 3.3.1. Inspection of mechanical stop, axis 1 Continued Inspection The procedure below details how to inspect the mechanical stop on axis 1 If the mechanical stop has been deformed after a hard collision, it must be replaced! Action Info/Illustration Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Page 95: Inspection Of Air Hoses (Foundry Prime)
3 Maintenance 3.3.2. Inspection of air hoses (Foundry Prime) 3.3.2. Inspection of air hoses (Foundry Prime) General The air hoses on Foundry Prime robots must be inspected for leakage every six month. Required equipment Equipment, etc. Art. no. Note Leak detection spray Pressure gauge cut off valve Procedure...
Page 96: Replacement Of Battery Pack, Measuring System
3 Maintenance 3.3.3. Replacement of battery pack, measuring system 3.3.3. Replacement of battery pack, measuring system Location of battery pack The battery pack is fit to the serial measurement unit, located inside the base. To access the unit and battery pack, the rear cover plate shown in the figure below must be removed. xx0300000106 Rear cover plate Required equipment...
Page 97 3 Maintenance 3.3.3. Replacement of battery pack, measuring system Continued Replacement, battery pack The procedure below details how to replace the battery pack in the serial measurement unit. Action Info/Illustration WARNING! The unit is sensitive to ESD, before handling the unit please observe the safety information in section WARNING - The unit is sensitive to ESD! on page 34 2.
Page 98: Cleaning Of Manipulator
3 Maintenance 3.3.4. Cleaning of manipulator 3.3.4. Cleaning of manipulator General Depending on the protection class, different methods of cleaning the manipulator are allowed. This section describes how to clean • the Standard version • the Foundry version Standard version The protection class is IP54.
Page 99: Change And Checking Of Oil
3 Maintenance 3.4.1. Oil in gearbox unit, axis 1-2-3 3.4 Change and checking of oil 3.4.1. Oil in gearbox unit, axis 1-2-3 General The oil in the gearbox unit, axis 1-2-3, is normally not changed. This section specifies the oil permitted in the unit.
Page 100: Inspection Of Oil Levels
3 Maintenance 3.4.2. Inspection of oil levels 3.4.2. Inspection of oil levels Location of oil plugs, axes 2 and 3 The oil plug, filling for the gearbox unit, axes 2 and 3, is located as shown in the figure below. The figure shows the location of the axis-2-side and is the same on the opposite side.
Page 101 3 Maintenance 3.4.2. Inspection of oil levels Continued Location of oil plugs, axes 5 and 6 (all robot versions except IRB 4400/L10) The wrist unit has two oil plugs for draining and one oil plug for filling, located as shown in the figure below.
Page 102 When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the type of oil specified by the manufacturer! If the oils are mixed, the gearbox must be thoroughly rinsed! Contact ABB for further instructions!
Page 103 3 Maintenance 3.4.2. Inspection of oil levels Continued Action Info/Illustration 3. Required oil level: 4 mm to the edge of the oil plug hole. 4. Fill with lubricating oil, if necessary. Type of oil is detailed in section Oil change, gearbox axis 4 on page 102.
Page 104: Oil Change, Gearbox Axis 4
3 Maintenance 3.4.3. Oil change, gearbox axis 4 3.4.3. Oil change, gearbox axis 4 Location of oil plugs The axis 4 gearbox has one oil plug for draining and one oil plug for filling, located as shown in the figure below. xx0300000220 Upper oil plug, filling Lower oil plug, draining...
Page 105 When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the type of oil specified by the manufacturer! If the oils are mixed, the gearbox must be thoroughly rinsed! Contact ABB for further instructions!
Page 106 3 Maintenance 3.4.3. Oil change, gearbox axis 4 Continued Action Note/Illustration 2. Remove the upper oil plug, filling. Shown in the figure Location of oil plugs on page 102. 3. Fill the gearbox with lubricating oil. Amount and art. no. is specified in Required equipment on page...
Page 107: Oil Change, Gearbox Axis 5 And 6 (All Robot Versions Except Irb 4400/L10)
3 Maintenance 3.4.4. Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10) 3.4.4. Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10) Location of oil plugs The wrist unit has two oil plugs for draining and one oil plug for filling, located as shown in the figure below.
Page 108 3 Maintenance 3.4.4. Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10) Continued Draining oil The procedure below details how to drain the oil from the wrist unit (axis 5 and 6). When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains quicker than cold oil.
Page 109 When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the type of oil specified by the manufacturer! If the oils are mixed, the gearbox must be thoroughly rinsed! Contact ABB for further instructions!
Page 110: Oil Change, Gearbox Axis 5 And 6 (Irb 4400/L10 Only)
3 Maintenance 3.4.5. Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) 3.4.5. Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) Location of oil plugs The wrist unit has one oil plug for draining the oil and one oil plug for filling, located as shown in the figure below.
Page 111 3 Maintenance 3.4.5. Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) Continued Draining oil The procedure below details how to drain the oil from the wrist unit (axis 5 and 6), robot version IRB 4400/L10. When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains quicker than cold oil.
Page 112 When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the type of oil specified by the manufacturer! If the oils are mixed, the gearbox must be thoroughly rinsed! Contact ABB for further instructions!
Page 113: Repair
4 Repair 4.1. Introduction 4 Repair 4.1. Introduction Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, e.g.
Page 114: General Procedures
4 Repair 4.2.1. Performing a leak-down test 4.2 General procedures 4.2.1. Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment Equipment, etc.
Page 115: Mounting Instructions For Bearings
4 Repair 4.2.2. Mounting instructions for bearings 4.2.2. Mounting instructions for bearings General This section details how to mount and grease different types of bearings on the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to grease the bearings, if not specified otherwise.
Page 116: Mounting Instructions For Seals
4 Repair 4.2.3. Mounting instructions for seals 4.2.3. Mounting instructions for seals General This sections details how to mount different types of seals to the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
Page 117 If the flange surfaces are defective, the parts may not be used because leakage could occur. 2. Clean the surfaces properly and in accordance with ABB recommendations. 3. Distribute the sealing compound evenly over the surface, preferably with a brush.
Page 118: Complete Robot
4 Repair 4.3.1. Replacement of cable harness, axes 1-3 4.3 Complete robot 4.3.1. Replacement of cable harness, axes 1-3 Location of cable harness, axes 1-3 The cable harness of axes 1-3 is located throughout the axis 1 of the robot as shown in the figure below.
Page 119 4 Repair 4.3.1. Replacement of cable harness, axes 1-3 Continued Location of cable harness, view X-X The cable guides in the middle of axis 1 are located as shown in the figure below. xx0300000110 Connection box, motor 1. Connectors at motor 1: R3.MP1, R3.FB1. Connection box, motor 2.
Page 120 4 Repair 4.3.1. Replacement of cable harness, axes 1-3 Continued Equipment, etc. Spare part no. Art. no. Note Circuit diagram See chapter Circuit diagram in the Product manual, reference infor- mation. Calibration Pendulum General calibration Instruction information is included in section Calibration information on page...
Page 121 4 Repair 4.3.1. Replacement of cable harness, axes 1-3 Continued Refitting, cabling axes 1-3 The procedure below details how to refit the cable harness to axes 1-3. Action Info/Illustration Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 122 4 Repair 4.3.1. Replacement of cable harness, axes 1-3 Continued Action Info/Illustration Make sure all safety requirements are met when performing the first test run. These are further detailed in section DANGER - First test run may cause injury or damage! on page 3HAC022032-001 Revision: E...
Page 123: Replacement Of Cable Harness, Axes 4-6
4 Repair 4.3.2. Replacement of cable harness, axes 4-6 4.3.2. Replacement of cable harness, axes 4-6 Location of cable harness, axes 4-6 The cable harness of axes 4-6 is located throughout the robot as shown in the figure below. Note! The figures show the robot model IRB 4400. But the location of the cable harness axes 4-6 on the IRB 4450S is basically the same.
Page 124 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Location of cable harness, view X-X The cable guides in the middle of axis 1 are located as shown in the figure below. xx0300000110 Connection box, motor 1. Connectors at motor 1: R3.MP1, R3.FB1. Connection box, motor 2.
Page 125 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Equipment, etc. Spare part no. Art. no. Note Circuit Diagram See chapter Circuit diagram in the Product manual, reference infor- mation. Calibration Pendulum Calibration is detailed in a Instruction separate calibration manual, enclosed with the calibration tools.
Page 126 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Action Info/Illustration 9. Loosen the cable brackets (A) between gearboxes 2 and 3 and cut the strap around them. xx0300000113 10. Feed the cabling and the air hose, if any, up through axis 1.
Page 127 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Connection box, upper arm The figure below shows the location of the motors, connectors and cabling in the upper arm connection box. xx0300000116 Axis 4 motor Connector R3.MP4 Connector R3.FB4 Axis 5 motor Connector R3.MP5 Connector R3.FB5...
Page 128 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Action Info/Illustration 2. Check the position of the three gaskets, located Part no. is specified in Required between the motors and the connection box. equipment on page 122. Replace them if damaged. 3.
Page 129 4 Repair 4.3.2. Replacement of cable harness, axes 4-6 Continued Action Info/Illustration 17. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 235.
Page 130: Replacement Of Complete Arm System
4 Repair 4.3.3. Replacement of complete arm system 4.3.3. Replacement of complete arm system Location of complete arm system The complete arm system includes the lower arm and the complete upper arm, as shown in the figure below. (The figure shows the IRB 4400.) A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
Page 131 4 Repair 4.3.3. Replacement of complete arm system Continued Spare part Equipment, etc. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See references required. to these procedures in the step-by-step instructions below.
Page 132 4 Repair 4.3.3. Replacement of complete arm system Continued Action Info/Illustration 5. Move the upper arm into a resting position against the lower arm. Lock the upper arm in this position with securing slings around the lower and upper arm (A), as shown in the figure to the right.
Page 133 4 Repair 4.3.3. Replacement of complete arm system Continued Refitting, complete arm system The procedure below details how to refit the complete arm system to the robot. Note! The following procedure also applies to the IRB 4450S. Action Info/Illustration Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 134 4 Repair 4.3.3. Replacement of complete arm system Continued Action Info/Illustration 5. Secure the arm system to the gearbox axis 2 10 pcs, M16x55. Tightening with the attachment screws and friction torque: 260 Nm. washers. Shown in the figure Location of Make sure both V-rings are seated properly! complete arm system on page 128 6.
Page 135: Upper Arm
4 Repair 4.4.1. Replacement of complete upper arm 4.4 Upper arm 4.4.1. Replacement of complete upper arm Location of upper arm The complete upper arm includes the wrist unit and is located as shown in the figure below. (The figure shows the IRB 4400.) A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
Page 136 4 Repair 4.4.1. Replacement of complete upper arm Continued Required equipment Spare part Equipment, etc. Art. no. Note Upper arm, without wrist 3HAC 17542-1 Foundry (also used for and motors standard) Sealing ring 3HAC 7877-1 Taper roller bearing 3HAA 2103-13 VK cover 3HAC 12165-1 Shaft end...
Page 137 4 Repair 4.4.1. Replacement of complete upper arm Continued Action Info/Illustration 3. Move the upper arm to a horizontal position. 4. Secure the weight of the upper arm with the lifting slings and a crane. 5. Remove the tie rod. Detailed in section Removal, tie rod on page 165...
Page 138 4 Repair 4.4.1. Replacement of complete upper arm Continued Action Info/Illustration 4. Lower the upper arm into mounting position. 5. Refit both shaft ends. Shown in the figure Location of upper arm on page 133. Part no. is specified in Required equipment on page 134.
Page 139 4 Repair 4.4.1. Replacement of complete upper arm Continued Action Info/Illustration 12. Refit the calibration plate, axis 3. Shown in the figure Location of upper arm on page 133. 13. Refit the connection box. Shown in the figure Location of upper arm on page 133.
Page 140: Replacement Of Wrist Unit
4 Repair 4.4.2. Replacement of wrist unit 4.4.2. Replacement of wrist unit Location of wrist unit The wrist unit is located in the upper arm as shown in the figure below. (The illustration shows the IRB 4400.) Removal/refitting procedures differs depending on robot version. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
Page 141 This component includes a complete unit comprising motors and gearboxes. It is a replacement unit of complex design and should not normally be serviced on-site. Instead it should be sent to ABB for service. ABB recommends its customers to carry out only the following servicing and repair work on this unit. Action...
Page 142 This component includes a complete unit comprising motors and gearboxes. It is a replacement unit of complex design and should not normally be serviced on-site. Instead it should be sent to ABB for service etc. ABB recommends its customers carry out only the following servicing/repair work on this unit. Action...
Page 143 4 Repair 4.4.2. Replacement of wrist unit Continued Action Info/Illustration 3. Apply flange sealing to the surface of the Specified in Required equipment on wrist that will seal against the upper arm page 138. tube. Sealing surface shown in the figure Location of wrist unit on page 138.
Page 144 This component includes a complete unit comprising motors and gearboxes. It is a replacement unit of complex design and should not normally be serviced on-site. Instead it should be sent to ABB for service etc. ABB recommends its customers carry out only the following servicing/repair work on this unit. Action...
Page 145 4 Repair 4.4.2. Replacement of wrist unit Continued Action Note/Illustration 7. Tighten the attachment screws and washers (A). xx0300000149 • A: 6 pcs, M8x30. Tightening torque: 34 Nm. 8. Check the play by moving axes 5 and 6 by hand. 9.
Page 146: Replacement Of Arm House Unit, Axis 4
4 Repair 4.4.3. Replacement of arm house unit, axis 4 4.4.3. Replacement of arm house unit, axis 4 Location of arm house unit The arm house unit includes the axis 4 housing and the upper arm tube. It is located as shown in the figure below.
Page 147 4 Repair 4.4.3. Replacement of arm house unit, axis 4 Continued Replacement, arm house unit The procedure below details how to replace the arm house unit. Note! The following procedure also applies to the IRB 4450S. Caution! The complete arm house unit weighs 152 kg! All lifting equipment used must be dimensioned accordingly! Action Info/Illustration...
Page 148 4 Repair 4.4.3. Replacement of arm house unit, axis 4 Continued Action Info/Illustration Make sure all safety requirements are met when performing the first test run. These are further detailed in section DANGER - First test run may cause injury or damage! on page 3HAC022032-001 Revision: E...
Page 149: Replacement Of Mechanical Stop, Axis 4
4 Repair 4.4.4. Replacement of mechanical stop, axis 4 4.4.4. Replacement of mechanical stop, axis 4 Location of mechanical stop The mechanical stop of axis 4 is located in the upper arm as shown in the figure below. (The figure shows the IRB 4400.) A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
Page 150 4 Repair 4.4.4. Replacement of mechanical stop, axis 4 Continued If the mechanical stop has been deformed after a hard collision, it must be replaced! When the damper is removed from axis 4, the axis does not have a mechanical stop! If the robot is provided with cabling on the upper arm, the cabling can be damaged when the function “Resetting the work area for an axis”...
Page 151 4 Repair 4.4.4. Replacement of mechanical stop, axis 4 Continued Action Note/Illustration 4. Fit the mechanical stop to the axis 4 with its Shown in the figure Location attachment screws. of mechanical stop on page 147. Part no. is specified in Required equipment on page 147.
Page 152: Replacement Of Signal Cabling, Upper Arm (Option 042)
4 Repair 4.4.5. Replacement of signal cabling, upper arm (option 042) 4.4.5. Replacement of signal cabling, upper arm (option 042) Location of signal cabling, upper arm The signal cabling (option 042) runs along the upper arm as shown in the figure below. xx03000000192 Wrist bracket Upper arm bracket...
Page 153 4 Repair 4.4.5. Replacement of signal cabling, upper arm (option 042) Continued Removal, signal cabling upper arm The procedure below details how to remove the signal cabling from the upper arm. Action Info/Illustration Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 154 4 Repair 4.4.5. Replacement of signal cabling, upper arm (option 042) Continued Action Note/Illustration 5. Refit the upper arm bracket to the upper arm. Location of the bracket is shown in the figure Location of signal cabling, upper arm on page 150.
Page 155 4 Repair 4.4.5. Replacement of signal cabling, upper arm (option 042) Continued Action Note/Illustration 9. Move axis 4 from one extreme limit to the other and back again. Caution! Caution! Check the cables during movement: • the cables must not be fully extended! •...
Page 156: Measuring The Play, Axis 5
4 Repair 4.4.6. Measuring the play, axis 5 4.4.6. Measuring the play, axis 5 General After reassembly due to repair work or any other reason, the play in axis 5 and 6 must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 5 is detailed below.
Page 157 4 Repair 4.4.6. Measuring the play, axis 5 Continued Action Info/Illustration 4. Apply load F in one direction, as shown in the figure to the right. Note! Different load and distances for the different robot versions, as specified to the right! xx0300000186 Values for robot version IRB 4400/...
Page 158 4 Repair 4.4.6. Measuring the play, axis 5 Continued Action Info/Illustration 6. Apply load F in the opposite direction, as shown in the figure to the right. xx0300000187 Values for robot version IRB 4400/ 45, /60, /L30, /S and IRB 4450S: •...
Page 159: Measuring The Play, Axis 6
4 Repair 4.4.7. Measuring the play, axis 6 4.4.7. Measuring the play, axis 6 General After reassembly due to repair work or any other reason, the play in axis 5 and 6 must be checked to ensure the repetition accuracy of the robot positioning. The procedure for axis 6 is detailed below.
Page 160 4 Repair 4.4.7. Measuring the play, axis 6 Continued Action Info/Illustration 3. Attach a weight (m) at a distance (B) from the wrist flange, in order to avoid the effects of play on axis 5. Note! Different weight and distance for the different robot versions, as specified to the right! xx0300000188...
Page 161 4 Repair 4.4.7. Measuring the play, axis 6 Continued Action Info/Illustration 6. Apply load F in the opposite direction, as shown in the figure to the right. xx0300000190 Values for robot version IRB 4400/ 45, /60, /L30, /S and IRB 4450S: •...
Page 162: Lower Arm
4 Repair 4.5.1. Replacement of lower arm 4.5 Lower arm 4.5.1. Replacement of lower arm Location of lower arm The lower arm is located as shown in the figure below. (The figure shows the IRB 4400.) A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
Page 163 4 Repair 4.5.1. Replacement of lower arm Continued V-ring between lower arm and gearbox axis 3 Required equipment Equipment, etc. Spare part no. Art. no. Note Lower arm 3HAC 5955-1 (IRB 4400/45, /60, /L10, /L30) Lower arm 3HAC 5956-1 (IRB 4400FS) Lower arm 3HAC 025476-001 (IRB 4450S)
Page 164 4 Repair 4.5.1. Replacement of lower arm Continued Action Info/Illustration 4. Remove the complete upper arm. Detailed in section Removal of complete upper arm. 5. Attach a crane to the lower arm and unload the weight. 6. Remove the balancing device. Detailed in section Replacement of balancing device on page...
Page 165 4 Repair 4.5.1. Replacement of lower arm Continued Action Info/Illustration 9. Refit the balancing device. Detailed in section Refitting of balancing device on page 10. Refit the upper arm. Detailed in section Refitting, upper arm on page 135 11. Refit the cabling. Detailed in section Refitting, cabling axes 4-6 on page...
Page 166: Replacement Of Tie Rod
4 Repair 4.5.2. Replacement of tie rod 4.5.2. Replacement of tie rod Location of tie rod The tie rod is located as shown in the figure below. (Figure shows the IRB 4400.) A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
Page 167 4 Repair 4.5.2. Replacement of tie rod Continued Required equipment Spare part Equipment, etc. Art. no. Note Washer 3HAB 3704-1 Replace if damaged. O-ring 3HAB 3772-23 Sealing, outside 3HAC 3297-1 Spherical roller bearing 3HAA 2167-11 Sealing, inside 3HAC 3990-11 Grease 3HAB 3537-1 Used to lubricate the shaft on the robot where the tie...
Page 168 4 Repair 4.5.2. Replacement of tie rod Continued Action Info/Illustration 3. Remove the two attachment screws. Shown in the figure Location of tie rod on page 164. 4. Remove the two washers, o-rings and sealings, Shown in the figure Location outside from the tie rod.
Page 169 4 Repair 4.5.2. Replacement of tie rod Continued Action Info/Illustration 8. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 235. Make sure all safety requirements are met when performing the first test run.
Page 170: Replacement Of Parallel Arm / Replacement Of Bearing
4 Repair 4.5.3. Replacement of parallel arm / Replacement of bearing 4.5.3. Replacement of parallel arm / Replacement of bearing Location of parallel arm The parallel arm is located on the robot, as shown in the figure below. (The figure shows the IRB 4400.) The bearing of the parallel arm is shown in the enlarged view.
Page 171 4 Repair 4.5.3. Replacement of parallel arm / Replacement of bearing Continued Required equipment Spare part Equipment, etc. Art. no. Note V-ring sealing 3HAB 3732-11 Groove ball bearing 3HAC 10905-1 Sealing ring 3HAB 3749-1 Grease 3HAB 3537-1 Used to lubricate the bearings and sealings.
Page 172 4 Repair 4.5.3. Replacement of parallel arm / Replacement of bearing Continued Action Info/Illustration 4. Loosen the attachment screws (A) so that the cabling can be moved slightly. xx0300000127 5. Remove the 10 attachment screws and the washer that holds the parallel arm to gearbox axis 3.
Page 173 4 Repair 4.5.3. Replacement of parallel arm / Replacement of bearing Continued Action Info/Illustration 5. Refit the washer and the 10 attachment 10 pcs. M16x80, 12.9 quality UNBRAKO. screws that hold the parallel arm to the Tightening torque: 260. gearbox unit. Reused screws may be used, providing they are lubricated as detailed in section Screw Joints in the Product manual,...
Page 174: Frame And Base
4 Repair 4.6.1. Replacement of balancing device 4.6 Frame and base 4.6.1. Replacement of balancing device Location of balancing device The balancing device is located as shown in the figure below. (The figure shows the IRB 4400.) A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference information.
Page 175 4 Repair 4.6.1. Replacement of balancing device Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Balancing device 3HAC 15083-1 Includes balancing device 3HAC 3702-1 (IRB 4400/45, /60, / L10, /L30 Includes cylindrical roller bearing 3HAC 4334-2 Includes front screws 3HAC 6456-1 Balancing device 3HAC 15083-2...
Page 176 4 Repair 4.6.1. Replacement of balancing device Continued Removal, balancing device The procedure below details how to remove the balancing device. Action Info/Illustration Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product doc- umentation! For example, attempting to open the balancing device is potentially lethal!
Page 177 4 Repair 4.6.1. Replacement of balancing device Continued Action Info/Illustration 5. Remove the two securing screws (A), located at the fork of the balancing device. Also remove the plate (C) which secures that the bushing (D) is held in position. xx0300000089 The fork is shown in the figure Location...
Page 178 4 Repair 4.6.1. Replacement of balancing device Continued Action Info/Illustration 8. Remove the four attachment screws, Shown in the figure Location of bracket from the bracket at the right side balancing device on page 172! of the balancing device (A), seen from above.
Page 179 4 Repair 4.6.1. Replacement of balancing device Continued Refitting of balancing device The procedure below details how to refit the balancing device. Action Info/Illustration Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal! Turn off all electric power, hydraulic and...
Page 180 4 Repair 4.6.1. Replacement of balancing device Continued Action Info/Illustration 9. Lubricate the bearing at the fork: • Remove the two stop screws (B). • Fill with grease through one of the lubrication holes, until excessive grease is forced out through the second hole.
Page 181 4 Repair 4.6.1. Replacement of balancing device Continued Action Info/Illustration Make sure all safety requirements are met when performing the first test run. These are further detailed in section DANGER - First test run may cause injury or damage! on page Fitting of cylindrical roller bearing The procedure below details how to fit the cylindrical roller bearings onto the balancing device shaft and into the frame brackets.
Page 182: Replacement Of Serial Measurement Unit
4 Repair 4.6.2. Replacement of serial measurement unit 4.6.2. Replacement of serial measurement unit Location of serial measurement unit The serial measurement unit is located inside the base of the robot, behind the rear cover, as shown in the figure below. xx0300000106 Rear cover plate Different versions, serial measurement unit...
Page 183 4 Repair 4.6.2. Replacement of serial measurement unit Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Serial measurement unit, 3HAC 17396-1 Includes battery version 3HAC16831-1 Serial measurement unit, 3HAC 16014-1 Does not include battery. version Battery pack, new version 3HAC 16831-1 Battery pack, old version 4944 026-4 Fastening plate, new...
Page 184 4 Repair 4.6.2. Replacement of serial measurement unit Continued Action Note/Illustration 7. Remove the connectors from the board. The connectors are shown in the figure Different versions, serial measurement unit on page 180. Refitting, serial measurement unit The procedure below details how to refit the complete serial measurement unit. Action Note/Illustration Turn off all electric power, hydraulic and pneumatic...
Page 185: Replacement Of Pushbutton Unit For Brake Release
4 Repair 4.6.3. Replacement of pushbutton unit for brake release 4.6.3. Replacement of pushbutton unit for brake release Location of pushbutton unit The pushbutton unit for brake release is located in the base of the robot, as shown in the figure below.
Page 186 4 Repair 4.6.3. Replacement of pushbutton unit for brake release Continued Removal, pushbutton unit The procedure below details how to remove the pushbutton unit from the robot. Action Info/Illustration Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 187 4 Repair 4.6.3. Replacement of pushbutton unit for brake release Continued Refitting of pushbutton unit The procedure below details how to refit the pushbutton unit to the robot. Action Note/Illustration Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 188: Replacement Of Mechanical Stop Pin, Axis 1
4 Repair 4.6.4. Replacement of mechanical stop pin, axis 1 4.6.4. Replacement of mechanical stop pin, axis 1 Location of mechanical stop pin The mechanical stop pin on axis 1 is located on the frame as shown in the figure below. (The figure shows the IRB 4400.) A more detailed view of the component and its position may be found in chapter Foldouts...
Page 189 4 Repair 4.6.4. Replacement of mechanical stop pin, axis 1 Continued Replacement, mechanical stop pin The procedure below details how to replace the mechanical stop pin on axis 1. If the mechanical stop has been deformed after a hard collision, it must be replaced! Action Info/Illustration Turn off all electric power, hydraulic and pneumatic...
Page 190: Motors
4 Repair 4.7.1. Replacement of motor, axis 1 4.7 Motors 4.7.1. Replacement of motor, axis 1 Location of motor The motor, axis 1, is located as shown in the figure below. (The figure shows the IRB 4400.) The motor and the drive gear constitute one unit. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
Page 191 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Spare part Equipment, etc. Art. no. Note Motor unit, axis 1 3HAC021729- Yaskawa (IRB 4400/S) Includes pinion O-ring, motor 2152 0431-11 Flange sealing 1234 0011-116 Loctite 574 Gasket 3HAC 4432-1 Between the motor and the connection box.
Page 192 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Removal, motor axis 1 The procedure below details how to remove the motor, axis 1. If a shelf-mounted robot version is not flat mounted, the manipulator can contain a living force! Removing the motor from axis 1 may result in movement of the axis, because the brake is released.
Page 193 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Refitting, motor axis 1 The procedure below details how to refit the motor, axis 1. Action Info/Illustration Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 194 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Action Info/Illustration 9. Fit the upper and lower screws (A, B) and tighten until there is no space between the motor flange and the gearbox. There should be a big backlash between the motor pinion and the gear.
Page 195 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Action Info/Illustration Make sure all safety requirements are met when performing the first test run. These are further detailed in section DANGER - First test run may cause injury or damage! on page 3HAC022032-001 Revision: E...
Page 196: Replacement Of Motor, Axis 2
4 Repair 4.7.2. Replacement of motor, axis 2 4.7.2. Replacement of motor, axis 2 Location of motor The motor, axis 2, is located as shown in the figure below. (The figure shows the IRB 4400.) The motor and the drive gear constitute one unit. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
Page 197 4 Repair 4.7.2. Replacement of motor, axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Measuring tool 3HAB 7887-1 Choose one of the two tools. 3HAB 1408-1 Other tools and These procedures include procedures may be references to the tools required.
Page 198 4 Repair 4.7.2. Replacement of motor, axis 2 Continued Action Info/Illustration 8. Remove the attachment screws and washers of the Shown in the figure Location motor. of motor on page 194. Note! Oil will start to run out when removing the motor! 9.
Page 199 4 Repair 4.7.2. Replacement of motor, axis 2 Continued Action Info/Illustration 9. Fit the upper and lower screws (A, B) and tighten until there is no space between the motor flange and the gearbox. There should be a big backlash between the motor pinion and the gear.
Page 200: Replacement Of Motor, Axis 3
4 Repair 4.7.3. Replacement of motor, axis 3 4.7.3. Replacement of motor, axis 3 Location of motor The motor, axis 3, is located as shown in the figure below. (The figure shows the IRB 4400.) The motor and the drive gear constitute one unit. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
Page 201 4 Repair 4.7.3. Replacement of motor, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note Measuring tool 3HAB 7887-1 Choose one of the two 3HAB 1408-1 tools. Other tools and These procedures include procedures may be references to the tools required.
Page 202 4 Repair 4.7.3. Replacement of motor, axis 3 Continued Action Info/Illustration 8. Remove the attachment screws and washers, motor. Shown in the figure Location of motor on page 198. Note! Oil will start to run out when removing the motor! 9.
Page 203 4 Repair 4.7.3. Replacement of motor, axis 3 Continued Action Info/Illustration 9. Fit the upper and lower screws (A, B) and tighten until there is no space between the motor flange and the gearbox. There should be a big backlash between the motor pinion and the gear.
Page 204: Adjustment Of Motors, Axes 1-3
4 Repair 4.7.4. Adjustment of motors, axes 1-3 4.7.4. Adjustment of motors, axes 1-3 General This section details how to adjust the motors during refitting. It applies to the motors in axes 1, 2 and 3 and is a complement to the refitting instructions found in sections •...
Page 205 4 Repair 4.7.4. Adjustment of motors, axes 1-3 Continued Action Info/Illustration 3. Release the brake of the current motor by Axis 1 motor: connect to connector connecting the 24VDC supply. R3.MP1 • +24V: pin 7 • 0V: pin 8. Axis 2 motor: connect to connector R3.MP2 •...
Page 206: Removal Of Motor, Axes 4, 5 And 6
4 Repair 4.7.5. Removal of motor, axes 4, 5 and 6 4.7.5. Removal of motor, axes 4, 5 and 6 Location of motors The motors, axes 4, 5 and 6, are located as shown in the figure below. (The figure shows the IRB 4400.) The motor and the drive gear of each axis constitute one unit.
Page 207 4 Repair 4.7.5. Removal of motor, axes 4, 5 and 6 Continued Spare part Equipment, etc. Art. no. Note Circuit Diagram See chapter Circuit diagram Product manual, reference information. Removal, motor axes 4, 5 and 6 The procedure below details how to remove the motors of axes 4, 5 and 6. Action Info/Illustration Turn off all electric power, hydraulic and pneumatic...
Page 208 4 Repair 4.7.5. Removal of motor, axes 4, 5 and 6 Continued Action Info/Illustration 9. Remove the attachment screws and washers, motor. Shown in the figure Location of motors on page 204. 10. Remove the motor. 3HAC022032-001 Revision: E...
Page 209: Refitting Of Motor, Axis 4
4 Repair 4.7.6. Refitting of motor, axis 4 4.7.6. Refitting of motor, axis 4 Location of motor The motors, axes 4, 5 and 6, are located as shown in the figure below. (The figure shows the IRB 4400.) The motor and the drive gear of each axis constitute one unit. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
Page 210 4 Repair 4.7.6. Refitting of motor, axis 4 Continued Equipment, etc. Spare part no. Art. no. Note Gasket 3HAC 3676-1 3 pcs Between the motors and the connection box. Replace if damaged. Standard toolkit 3HAC 17594-1 The contents are defined in section Standard toolkit on page 264.
Page 211 4 Repair 4.7.6. Refitting of motor, axis 4 Continued Action Info/Illustration 5. Fit the o-ring to the new motor unit. Part no. is specified in Required equipment on page 207. 6. Fit the measuring tool to the rear of the motor. Art. no. is specified in Required equipment on page 207.
Page 212: Refitting Of Motor, Axis 5
4 Repair 4.7.7. Refitting of motor, axis 5 4.7.7. Refitting of motor, axis 5 Location of motor The motors, axes 4, 5 and 6 are located as shown in the figure below. (The figure shows the IRB 4400.) The motor and drive gear of each axis constitutes one unit. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
Page 213 4 Repair 4.7.7. Refitting of motor, axis 5 Continued Equipment, etc. Spare part no. Art. no. Note O-ring 2152 2012-426 Gasket 3HAC 3676-1 3 pcs Between the motor and the connection box. Replace if damaged. Standard toolkit 3HAC The contents are defined in 17594-1 section Standard toolkit on page 264.
Page 214 4 Repair 4.7.7. Refitting of motor, axis 5 Continued Action Info/Illustration 5. Fit the o-ring into the new motor. Part no. is specified in Required equipment on page 210. 6. Fit the measuring tool to the rear of the motor. Art.
Page 215 4 Repair 4.7.7. Refitting of motor, axis 5 Continued Action Info/Illustration Make sure all safety requirements are met when performing the first test run. These are further detailed in section DANGER - First test run may cause injury or damage! on page 3HAC022032-001 Revision: E...
Page 216: Refitting Of Motor, Axis 6
4 Repair 4.7.8. Refitting of motor, axis 6 4.7.8. Refitting of motor, axis 6 Location of motor The motors, axes 4, 5 and 6, are located as shown in the figure below. (The figure shows the IRB 4400.) The motor and the drive gear of each axis constitute one unit. A more detailed view of the component and its position may be found in chapter Foldouts Product manual, reference...
Page 217 4 Repair 4.7.8. Refitting of motor, axis 6 Continued Equipment, etc. Spare part no. Art. no. Note O-ring 2152 2012-426 Gasket 3HAC 3676-1 3 pcs Between the motors and the connection box. Replace if damaged. Standard toolkit 3HAC 17594-1 The contents are defined in section Standard toolkit on page 264.
Page 218 4 Repair 4.7.8. Refitting of motor, axis 6 Continued Action Info/Illustration 5. Fit the o-ring to the new motor unit. Part no. is specified in Required equipment on page 214. 6. Fit the measuring tool at the rear of the motor. Art.
Page 219 4 Repair 4.7.8. Refitting of motor, axis 6 Continued Action Info/Illustration 19. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information na str 235. Make sure all safety requirements are met when performing the first test run.
Page 220: Gearboxes
4 Repair 4.8.1. Replacement of gearbox unit, axes 1-2-3 4.8 Gearboxes 4.8.1. Replacement of gearbox unit, axes 1-2-3 General The gearboxes of axes 1-2-3 are handled as one complete unit. Except for the gearboxes, the spare part also includes motor units and lubricating oil for the axes 1, 2 and 3. Location of gearbox unit The gearbox unit, axes 1-2-3, is shown in the figure below.
Page 221 4 Repair 4.8.1. Replacement of gearbox unit, axes 1-2-3 Continued Equipment, etc. Spare part no. Art. no. Note Standard toolkit 3HAC 17594-1 The contents are defined in section Standard toolkit on page 264. Lifting slings with hoisting Lifting capacity: 500 kg. block Other tools and These procedures...
Page 222 4 Repair 4.8.1. Replacement of gearbox unit, axes 1-2-3 Continued Action Info/Illustration 5. Remove the tie rod. Detailed in section Replacement of tie rod on page 164. 6. Remove the parallel arm. Detailed in section Replacement of parallel arm / Replacement of bearing on page 168.
Page 223 4 Repair 4.8.1. Replacement of gearbox unit, axes 1-2-3 Continued Action Info/Illustration 11. Place the assembly on a level surface and support it at position A, according to the figure on the right. Make sure the unit is stable and rests securily before removing the lifting equipment.
Page 224 4 Repair 4.8.1. Replacement of gearbox unit, axes 1-2-3 Continued Action Info/Illustration The gearbox unit weighs 360 kg (robot version IRB 4400/45, /60, /L30, /L10 and IRB 4400/S) or 475 kg (robot version IRB 4450S)! All lifting equipment used must be sized accordingly! The base weighs 130 kg! All lifting equipment used must be sized accordingly!
Page 225 4 Repair 4.8.1. Replacement of gearbox unit, axes 1-2-3 Continued Action Info/Illustration 7. Refit the base with the attachment screws Shown in figure Location of gearbox and washers, gearbox unit. unit on page 218 14 pcs, M16x80. 12.9 quality UNBRAKO. Tightening torque: 260 Reused screws may be used, providing they are lubricated as detailed in Screw joints in the Product...
Page 226: Adjusting Play On Axis 4, Intermediate Gear
4 Repair 4.8.2. Adjusting play on axis 4, intermediate gear 4.8.2. Adjusting play on axis 4, intermediate gear Illustration, adjusting play In order to adjust the play on axis 4, the gear must be accessible. The figure below shows the parts in the upper arm housing that must be removed/unlocked.
Page 227 4 Repair 4.8.2. Adjusting play on axis 4, intermediate gear Continued Adjusting play, axis 4 The procedure below details how to adjust the play for the intermediate gear of axis 4. Action Info/Illustration Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 228: Additional Repair Routines (Foundry Prime)
4 Repair 4.9.1. Introduction 4.9 Additional repair routines (Foundry Prime) 4.9.1. Introduction Overview Robots working with water jet cleaning have special tightness for water jet cleaning application and require special repair routines to maintain the tightness level. The repair must be done according to the repair chapter, with the following additions as described in the Repair routines procedure below.
Page 229 4 Repair 4.9.2. Repair routines Continued Action Note/Illustration 3. Apply sikaflex 521FC outside the gasket and the cover plate around the motor. xx0600003112 • A: Sikaflex 4. Apply sikaflex 521FC underneath the cover attachment screw heads. xx0600003113 • A: Sikaflex Continues on next page 3HAC022032-001 Revision: E...
Page 230 4 Repair 4.9.2. Repair routines Continued Replacement of cable harness to motor axes 1-3 and 4-6 The following procedure details how to replace motor cabling axes 1-3 and 4-6. Action Note/Illustration 1. Drill and tap holes in the cable boxes for the Cable box, motr unit axes 1-3 air fittings before mounting a new cable harness.
Page 231 4 Repair 4.9.2. Repair routines Continued Replacement of balancing device The following procedure details how to replace the balancing device. Action Note/Illustration 1. Before mounting the balanicing device in the robot, apply mercasol 3106 on both side of the ear and both side of the washers. xx0600003123 •...
Page 232 4 Repair 4.9.2. Repair routines Continued Equipment Article number/QTY Note/Illustration Elbow fitting 3HAC026511-001/ 1 Pos 6 in figure above Rubber clamp 3HAC026523-001 T-plug connector 3HAC026515-001/ 2 Pos 3 in figure above Y-plug connector 3HAC026514-001/ 3 Pos 2 in figure above Bulkhead plug connector 3HAC026513-001/ 1 Pos 1 in figure above...
Page 233 4 Repair 4.9.2. Repair routines Continued Pneumatic Article number Note house 3HAC026526-001 425 mm From the Y-plug connector at axis 3 motors to the straight fitting in the motor cover axis 3. 80 mm From the Y-plug connector at axis 3 to the Y-plug connector for the balancing cylinder.
Page 234 4 Repair 4.9.2. Repair routines Continued Action Note/Illustration 3. In the base an extra ring of the hose is made so that full movement for axis 1 is guaranteed. xx0600003118 4. -The plastic hose is drawn from the T-plug connector up through axis 1.-A hole is drilled in the cable guide axis 1 for the air hose.
Page 235 4 Repair 4.9.2. Repair routines Continued Action Note/Illustration 6. The hose is led back down the lower arm to motors axis 1-3 from the Y-plug connector. The air is distributed via a Y-plug connector and a T-plug connector to the cable boxes xx0600003120 xx0600003122 7.
Page 236 4 Repair 4.9.2. Repair routines 3HAC022032-001 Revision: E...
Page 237: Calibration Information
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in section Calibration methods on page 236, and further detailed in separate Calibration manuals.
Page 238: Calibration Methods
5 Calibration information 5.2. Calibration methods 5.2. Calibration methods Overview This section specifies the different types of calibration and the calibration methods that are supplied from ABB. Types of calibration Type of calibra- Description Calibration method tion Standard The calibrated robot is positioned at home...
Page 239 Calibration Pendulum - standard method Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.
Page 240: Calibration Scales And Correct Axis Position
5 Calibration information 5.3. Calibration scales and correct axis position 5.3. Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales, IRB 4450S The illustration below shows the calibration scale positions on IRB 4450S. The calibration marks for axes 2, 3, 4 and 5 are marked using punch mark tools.
Page 241 5 Calibration information 5.3. Calibration scales and correct axis position Continued Calibration scales, IRB 4400 The illustration below shows the calibration scale positions on IRB 4400. The calibration marks for axes 2, 3, 4 and 5 are marked using punch mark tools. xx0300000209 Punch, axis 2, 3HAB 1521-1 Punch, axis 3, 3HAB 1522-1...
Page 242: Calibration Movement Directions For All Axes
5 Calibration information 5.4. Calibration movement directions for all axes 5.4. Calibration movement directions for all axes Overview When calibrating, the axis must consistently be run towards the calibration position in the same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions are shown in the figure below.
Page 243: Updating Revolution Counters
5 Calibration information 5.5. Updating revolution counters 5.5. Updating revolution counters General This section details how to perform a rough calibration of each robot axis, i.e. updating the revolution counter value for each axis, using the pendant. Step 1 - Manually running the robot to the calibration position This procedure details the first step when updating the revolution counter;...
Page 244 5 Calibration information 5.5. Updating revolution counters Continued Action Note 2. Select Calibration from the View menu. The Calibration window appears. If there is more than one unit connected to the robot, they will be listed in the window. xx0100000201 3.
Page 245 This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0). Action 1. On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status.
Page 246 5 Calibration information 5.5. Updating revolution counters Continued Action If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. See section Checking the calibration position on page 245.
Page 247: Checking The Calibration Position
This section describes how to create a program, which runs all the robot axes to their zero position. Action Note 1. On ABB menu tap Program Editor. 2. Create a new program. 3. Use MoveAbsJ in the Motion&Proc menu. 4. Create the following program: MoveAbsJ...
Page 248 This section describes how to jog the robot to all axes zero position. Action Note 1. Tap Jogging in the ABB menu. 2. Tap Motion mode to choose group of axes to jog. 3. Tap axes 1-3 to jog axes 1, 2 or 3.
Page 249: Additional Calibration Instruction, Irb4400
5 Calibration information 5.7. Additional calibration instruction, IRB4400 5.7. Additional calibration instruction, IRB4400 Instrauction Before updating the revolution counters (coarse calibration) on IRB 4400, the stainless steel metal ring on axis 4 need to be removed. Illustration xx0600003124 Upper arm Stainless steel ring hose clamp Continues on next page...
Page 250 5 Calibration information 5.7. Additional calibration instruction, IRB4400 Continued 3HAC022032-001 Revision: E...
Page 251: Overview
Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters:...
Page 252 Overview Continued Revisions Revision Description First edition. Replaces previous manuals: • Installation and Commissioning Manual • Maintenance Manual • Repair Manual, part 1 • Repair Manual, part 2. Changes made in the material from the previous manuals: • Model M2004 implemented. Section Document references is completed with article numbers for calibration manuals.
Page 253: Product Documentation, M2000/M2000A
A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation. Each document set contains the types of information specified below: •...
Page 254: Product Documentation, M2004
This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems.
Page 255 Product documentation, M2004 Continued Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: • The purpose of the application (what it does and when it is useful) •...
Page 256 Product documentation, M2004 3HAC022032-001 Revision: E...
Page 257: Reference Information
6 Reference information 6.1. Introduction 6 Reference information 6.1. Introduction General This chapter includes general information, complementing the more specific information in Product manual (part 1 of 2), procedures. 3HAC022032-001 Revision: E...
Page 258: Applicable Safety Standards
6 Reference information 6.2. Applicable safety standards 6.2. Applicable safety standards Safety standards The robot conforms to the following standards: • EN 292-1 - Safety of machinery, terminology • EN 292-2 - Safety of machinery, technical specifications • EN 954-1 - Safety of machinery, safety related parts of control systems •...
Page 259: Unit Conversion
6 Reference information 6.3. Unit conversion 6.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...
Page 260: Screw Joints
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.
Page 261 6 Reference information 6.4. Screw joints Continued Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description.
Page 262 6 Reference information 6.4. Screw joints Continued The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Tightening torque Tightening torque Tightening torque Dimension Nm - Nominal Nm - Min.
Page 263: Weight Specifications
All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model.
Page 264: Document References
6 Reference information 6.6. Document references 6.6. Document references General The contents of this manual may include references to additional documentation necessary to perform certain procedures. This section specifies the article numbers for the referenced documentation. Product specification, robot The product specification includes generic technical data. The specification listed below is the English version.
Page 265 6 Reference information 6.6. Document references Continued Calibration manuals Document name Document ID Note Calibration Pendulum 3HAC16578-1 Enclosed with the Calibration Instruction Pendulum tool set Instructions for Levelmeter 3HAC022907-001 Enclosed with the Levelmeter 2000. calibration (alternative method) CalibWare 2.0 Users Guide 3HAC16090-1 Manual for Absolute Accuracy calibra- tion.
Page 266: Standard Toolkit
6 Reference information 6.7. Standard toolkit 6.7. Standard toolkit General All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.
Page 267 6 Reference information 6.7. Standard toolkit Continued Contents, standard toolkit Tool Allen key 5-17 mm Socket with ratchet Box spanner set Screwdriver Torx socket no:20, 25, 30 Extension bar 100 mm Puller bar KM nut (KM10, KM17) Lifting hoist Cutting pliers Torque wrench 10-470 Nm 3HAC022032-001 Revision: E...
Page 268: Special Tools
6 Reference information 6.8. Special tools 6.8. Special tools General All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section Standard toolkit on page 264, and of special tools, listed directly in the instructions and also gathered in this section.
Page 269 6 Reference information 6.8. Special tools Continued Special tools The table below specifies the special tools required during several of the service procedures. The tools may be ordered separately and are also specified directly in concerned instructions in the Product manual, procedures.
Page 270 3HAC021984-001 Tools that may be rented The table below specifies the tools that may be rented from ABB in order to perform certain service procedures as described in the Product manual. The special tools are also listed directly in the instructions.
Page 271 6 Reference information 6.8. Special tools Continued Description Art. no. Note Dismounting tool, shaft ends 3HAB9009-1 Used for removing the shafts from the upper arm. Mounting tool, bearing 3HAB 6464-1 Adjustment tool 3HAA7601-50 Special tools The table below specifies the special tools required during service procedures. The tools are also specified directly in concerned procedures for repair.
Page 272 6 Reference information 6.8. Special tools Continued Item Description Art. no. Note Connection rod 3HAC025192-006 M16, length= 280 mm 3HAC023963-029 Press washer 3HAC023963-014 D= 70 mm Press head 3HAC023963-039 D= 55 mm Sleeve 3HAC023963-037 D= 55 mm Press sleeve 3HAC023963-015 D= 70 mm Connecting rod 3HAC023081-003...
Page 273 6 Reference information 6.8. Special tools Continued Mounting tool, bearing race and sealing, upper arm. Assembly is shown in the figure Mounting tool, bearing race and sealing, upper arm on page 273. Dismounting tool, bearing race, upper arm. Assembly is shown in the figure Dismounting tool, bearing race, upper arm on page 273.
Page 274 6 Reference information 6.8. Special tools Continued Mounting tool, tilthouse shaft The tool for fitting the tilthouse shaft to the tilthouse is assembled with the parts shown in the figure below (included in the toolkit for service). Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are given only for identification.
Page 275 6 Reference information 6.8. Special tools Continued Mounting tool, bearing race and sealing, upper arm The tool for fitting the bearing race and sealing to the upper arm is assembled with the parts shown in the figure below (included in the toolkit for service). Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are given only for identification.
Page 276 6 Reference information 6.8. Special tools Continued Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25 Nut, 3HAC5507-1 Sleeve, 3HAC023963-027 Nut, 3HAC023963-028 Press sleeve, 3HAC023963-038 Connection rod, 3HAC025192-006 Dismounting tool, bearing race, tilthouse shaft The tool for removing the bearing race from the tilthouse shaft is assembled with the parts shown in the figure below (included in the toolkit for service).
Page 277 6 Reference information 6.8. Special tools Continued Mounting tool, bearing race, tilthouse shaft The tool for fitting a bearing race to the tilthouse shaft is assembled with the parts shown in the figure below (included in the toolkit for service). Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are given only for identification.
Page 278 6 Reference information 6.8. Special tools Continued Press tool, link The tool for fitting the bearing and the link to the upper arm shaft includes the parts shown in the figure below (included in the toolkit for service). Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are only given for identification! xx0600002618 Hydraulic cylinder, 3HAC11731-1...
Page 279 6 Reference information 6.8. Special tools Continued Calibration equipment, Calibration Pendulum The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method. Description Art. no. Note Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual.
Page 280 6 Reference information 6.8. Special tools Continued Lifting tool The table below specifies the lifting tools required during several of the service procedures. The tools may be ordered separately and are also specified directly in concerned instructions in the Product manual, procedures. Description Art.
Page 281 6 Reference information 6.8. Special tools Continued Special tools The table below specifies the special tools required during several of the service procedures. The tools may be ordered separately and are also specified directly in concerned instructions in the Product manual, procedures.
Page 282: Lifting Equipment And Lifting Instructions
6 Reference information 6.9. Lifting equipment and lifting instructions 6.9. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.
Page 283: Part List
7 Part list 7.1. Introduction 7 Part list 7.1. Introduction Overview This section specifies all the replacement articles of the robot. The parts are shown in exploded views or in foldouts, either in this or in a separate chapter. Specific spare parts are listed separately in a Spare part list. 3HAC022032-001 Revision: E...
Page 284: Manipulator
7 Part list 7.2. Manipulator 7.2. Manipulator Part list, manipulator See the Foldout 1, 2, 3:1, 3:2, 4 and 5 for location of parts. Item Qty Name Art.no Note Foot 3HAC 5947-1 Gear box axes 1-3 3HAC 5948-1 /45, /60, L/10 Gear box axes 1-3 3HAC 5949-1 /FS, L/30...
Page 285 7 Part list 7.2. Manipulator Continued Item Qty Name Art.no Note Washer 3HAC 4160-1 Balancing unit 3HAC 15083-1 /45, /60, L/10, L/30 Balancing unit 3HAC 15083-2 Balancing unit 3HAC025477-001 IRB 4450S Shaft 3HAC 3970-1 Needle roller bearing 3HAB 3757-17 Securing plate 3HAC 4168-1 Stop pin 3HAB 3647-1...
Page 286 7 Part list 7.2. Manipulator Continued Item Qty Name Art.no Note Sealing with dustlip 3HAC 7877-1 Tapper roller bearing 3HAA 2103-13 VK-cover 3HAA 2166-11 80x10 Lock nut 2126 2851-110 M50x1.5 Shaft end 3HAC 4744-1 Sync. market axis 2 3HAB 3754-1 Washer 3HAA 2356-13 6.4x22x1.5...
Page 287 7 Part list 7.2. Manipulator Continued Item Qty Name Art.no Note Screw 2121 2477-291 M4x12 Housing 64-p 5217 687-22 /45 /60 L/10 L/30 and IRB 4450S Protection cover 64-p 3HAC 7818-1 F/45 F/60 FL/30, FS Designition sign 3HAB 8431-1 Screw 9ADA 629-43 M5x10 Bracket...
Page 288: Upper Arm Part, Axes 4-6
7 Part list 7.3. Upper arm part, axes 4-6 7.3. Upper arm part, axes 4-6 Part list, upper arm part See the Foldout 6:1, 6:2 and 6:3 for location of parts. Item Qty Name Art.no Note Upper arm without 3HAC 17542-1 Foundry, but also used for std wrist and motors.
Page 289 7 Part list 7.3. Upper arm part, axes 4-6 Continued Item Qty Name Art.no Note Motor unit axis 5 3HAC 10603-1 /45, /60, /L30, /FS with pinion (Elmo) Motor unit axis 4 3HAC 021726-001 /45, /60, /L30, FS and IRB 4450S with pinion (Yaskawa) Motor unit axis 4...
Page 290 7 Part list 7.3. Upper arm part, axes 4-6 Continued Signal cabling, upper arm xx0300000409 3HAC022032-001 Revision: E...
Page 291: Serial Measurement Unit
7 Part list 7.4. Serial measurement unit 7.4. Serial measurement unit Part list, serial measurement unit See the Foldout 7 for location of parts. Item Qty Name Art.no. Note Battery pack, new 3HAC 16831-1 Lithium Battery pack, old 4944 026-4 NiCd 7.2 V 4 Ah Straps, outdoor 2166 2055-6...
Page 292: Position Switch, Axis 1
7 Part list 7.5. Position switch, axis 1 7.5. Position switch, axis 1 Part list, position switch See the Foldout 8 for location of parts. Item Qty Name Art.no. Note Pos. switch ax 1, 1 sw 3HAC 12042-1 Option 25-2 Standard, complete set Pos.
Page 293 7 Part list 7.5. Position switch, axis 1 Continued Item Qty Name Art.no. Note Torx pan head roll. screw 9ADA 618-54 Steel 8.8-A2F, M6x10ax1possw(two) Torx pan head roll. screw 9ADA 618-54 Steel 8.8-A2F, M6x10ax1possw(three) Bracket position switch 3HAC 8057-1 Limit position switch Hexagon nut 9ADA 267-5 Steel 8-A2F, M5...
Page 294 7 Part list 7.5. Position switch, axis 1 3HAC022032-001 Revision: E...
Page 295: Foldouts
8 Foldouts 8.1. Introduction 8 Foldouts 8.1. Introduction Definitions This chapter contains detailed views of the components on the manipulator. The numbered details are specified with item numbers in the Part List. The foldouts are divided into: • Foldout 1: Manipulator (part list: Manipulator on page 282) •...
Page 297: Circuit Diagram
Foldout 1...
Page 298 Foldout 2...
Page 299 Foldout 3:1...
Page 300 IRB 4450S WARNING ACHTUNG ATTENTION 1.72 1.73 1.71 W ARNING ACHTUNG ATTENTION WARNING ACHTUNG ATTENTION Foldout 3:2...
Page 301 Foldout 4...
Page 302 Foldout 5...
Page 303 Foldout 6:1...
Page 304 Foldout 6:2...
Page 305 Foldout 6:3...
Page 306 3hab 3365-1/x Seriemätenhet R1.G R2.SMB R1. SMB Foldout 7...
Page 307 Foldout 8...
Page 308 9 Circuit diagram 8.1. Introduction 9 Circuit diagram 3HAC022032-001 Revision: E...
Page 309 9 Circuit diagram 8.1. Introduction 3HAC022032-001 Revision: E...
Page 310 Circuit Diagram CONTENTS Page Manipulator, diagram 3HAC 9821-3, Rev. 0 ..............101-108 Product Manual IRB 4400...
Page 311 Sheet 101 List of Contents / Location of Connection Point...
Page 312 Brake Release Unit / Serial Measurement Board Sheet 102...
Page 313 Motor Axis 1 - 3 Sheet 103...
Page 314 Feed-Back Axis 1 - 3 Sheet 104...
Page 315 Sheet 105 Motor Axis 4 - 6...
Page 316 Feed-Back Axis 4 - 6 Sheet 106...
Page 317 Customer Connection Sheet 107...
Page 318 Pos. Indicator Axis 1, Option Sheet 108...
Page 319 Index Absolute Accuracy, calibration 237 Levelmeter calibration 237 brakes mechanical stop testing function 25 axis 1 66 axis 2 69 MoveAbsJ instruction calibrating FlexPendant 245 roughly 241 TPU 245 calibration Absolute Accuracy type 236 alternative method 237 negative directions, axes 240 Levelmeter calibration 237 marks/scales 238 oil change...
Page 320 Index testing, brakes 25 tools calibration equipment, Levelmeter 276 Calibration Pendulum equipment 277 dismounting tilthouse shaft 271 for service 266 hydraulic pump 269 mounting shaft and bearings at link 271 mounting tilthouse bearing race and sealing 271 mounting tilthouse shaft 270 oil exchange equipment 277 jogging to calibration position 246 MoveAbsJ instruction 245...
Page 322 ABB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

This manual is also suitable for:

Irb 4400 - 60 Irb 4400 - l10 Irb 4400 - l30 Irb 4400 - ls

ABB IRB 4400 - 45 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration Information

6 Reference Information

7 Part List

8 Foldouts

9 Circuit Diagram

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