Product manual

Articulated robot

IRB 4400/45
IRB 4400/60
IRB 4400/L30
IRB 4400/L10
IRB 4400 - S
IRB 4450S
M2004
 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: H
© Copyright 2004-2010 ABB. All rights reserved.
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.

© Copyright 2004-2010 ABB. All rights reserved.

© Copyright 2004-2010 ABB All rights reserved.

ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
 Table of Contents

Overview of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1 Safety 13
1.1 Introduction to safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Safety in the manipulator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety risks during installation and service work on manipulators. . . . . . . . . . . . . . . . . . 15
1.2.2.2 CAUTION - Hot parts may cause burns! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.2.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.2.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.2.6 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.3 Emergency release of the manipulator’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.3.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.4 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.4.1 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3.1 Safety signals in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3.2 Safety symbols on the manipulator labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.3 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.3.4 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.3.5 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3.6 WARNING - Safety risks during work with gearbox lubricants (oil or grease) . . . . . . . . . . . . . . 42

2 Installation and commissioning 45

© Copyright 2004-2010 ABB. All rights reserved.

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2.2 Working range, IRB 4400/45 and /60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.2.3 Working range, IRB 4400/L30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.2.4 Working range, IRB 4400/L10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.2.5 Working range, IRB 4400/S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.2.6 Working range, IRB 4450S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2.7 Risk of tipping/stability - IRB 4450S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3.1 Lifting robot with round slings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3.3 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3.4 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.4.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

3HAC022032-001 Revision: H 3
Table of Contents

2.4.4 Electrically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

2.4.5 Unlimited working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.5.1 Customer connection on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.5.2 Customer connections on upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.6 Additional installation (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.6.1 Installation of IRB4400 in a water jet application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.6.2 Commissioning (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.7 Making robot ready for operation, Clean room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.7.1 Additional installation procedure, Clean room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

3 Maintenance 93
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.3 General maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.3.1 Inspection of mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.3.2 Inspection of air hoses (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.3.3 Inspection of surface treatment (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.3.4 Replacement of battery pack, measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.3.5 Cleaning, robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.4 Change and checking of oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.4.1 Oil in gearbox unit, axis 1-2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.4.2 Inspection of oil levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.4.3 Oil change, gearbox axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.4.4 Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10) . . . . . . . . . . . . . . . 114
3.4.5 Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

4 Repair 121
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
© Copyright 2004-2010 ABB. All rights reserved.
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.3.1 Replacement of cable harness, axes 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.3.2 Replacement of cable harness, axes 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.3.3 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.4 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.4.1 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.4.2 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.4.3 Replacement of arm house unit, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.4.4 Replacement of mechanical stop, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.4.5 Replacement of signal cabling, upper arm (option 042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.4.6 Measuring the play, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.4.7 Measuring the play, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.5 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.5.1 Replacement of lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.5.2 Replacement of tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.5.3 Replacement of parallel arm / Replacement of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

4 3HAC022032-001 Revision: H
 Table of Contents

4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

4.6.1 Replacement of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.6.2 Replacement of serial measurement unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4.6.3 Replacement of pushbutton unit for brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.6.4 Replacement of mechanical stop pin, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.7.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.7.2 Replacement of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.7.3 Replacement of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.7.4 Adjustment of motors, axes 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.7.5 Removal of motor, axes 4, 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.7.6 Refitting of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.7.7 Refitting of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.7.8 Refitting of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.8.1 Replacement of gearbox unit, axes 1-2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.8.2 Adjusting play on axis 4, intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
4.9 Additional repair routines (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4.9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4.9.2 Repair routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

5 Calibration information 247

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
5.3 Calibration scale and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
5.7 Additional calibration instruction, IRB4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

6 Decommissioning 261
6.1 Environmental information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
6.2 Decommissioning of balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

7 Reference information 265

© Copyright 2004-2010 ABB. All rights reserved.

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

7.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
7.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
7.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
7.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
7.7 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
7.8 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
7.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

8 Part list 279

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
8.2 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
8.3 Upper arm part, axes 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
8.4 Serial measurement unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.5 Position switch, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

9 Foldouts 289
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

3HAC022032-001 Revision: H 5
Table of Contents

10 Circuit diagram 291

10.1 About circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Index 293

© Copyright 2004-2010 ABB. All rights reserved.

6 3HAC022032-001 Revision: H
 Overview of this manual

Overview of this manual

About this manual

This manual contains instructions for
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The manual also contains reference information for all procedures detailed in the manual.

Usage
This manual should be used during
• installation, from lifting the robot to its work site and securing it to the foundation to
making it ready for operation
• maintenance work
• repair work.

Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.

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
© Copyright 2004-2010 ABB. All rights reserved.

The manual is organized in the following chapters:

Chapter Contents
Safety, service Safety information
Installation and commissioning Information about installation of the robot.
Maintenance Information about maintenance work, including
maintenance schedules.
Repair Information about repair work.
Calibration information Procedures that does not require specific calibration
equipment. General information about calibration.
Decommissioning Environmental information about the robot and its
components.
Reference information Useful information when performing installation,
maintenance or repair work (lists of necessary tools,
reference documents, safety standards.
Part list Complete list of robot parts, shown in the exploded views or
foldouts.

Continues on next page

3HAC022032-001 Revision: H 7
Overview of this manual

Continued

Chapter Contents
Exploded views / Foldouts Detailed illustrations of the robot with reference numbers to
the part list.
Circuit diagram Reference to the circuit diagram for the robot.

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.
A Chapter Safety, service replaced with chapter Safety.
Chapter Calibration replaced with chapter Calibration information.
Removed chapter Calibration, M2004.
Section Document references is completed with article numbers for calibration
manuals.
B Yaskawa motors been added.
C Robot model IRB 4450S added.
D Foundry Prime (Water jet application) added.
E Cleanroom added.
Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
F Content updated in chapter/section:
• Section What is an emergency stop? added to chapter Safety.
• Maintenance/Maintenance schedule: Interval for replacement of battery

© Copyright 2004-2010 ABB. All rights reserved.

pack changed
• Maintenance/Cleaning of robot
G Missing spare part in chapter Spare parts, section Upper arm, axes 4-6, added:
• Item 29, Gear axis 6
H This revision includes the following addtions and/or changes:
• Inspection of surface treatment added to Maintenance schedule on page
95 (Foundry Prime).
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagram on page 291.
• List of standards updated, see Applicable safety standards on page 266.
• Decommissioning chapter added.
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 32.
• New safety labels on the manipulators, see Safety symbols on the
manipulator labels on page 34.
• Revised terminology: robot replaced with manipulator.

8 3HAC022032-001 Revision: H
 Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:

Product manuals
All hardware, manipulators and controllers will be delivered with a Product manual that
contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation, electrical
connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals).
• Repair (descriptions of all recommended repair procedures including spare parts).
• Additional procedures, if any (calibration, decommissioning).
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards).
• Parts list.
• Foldouts or exploded views.
• Circuit diagrams (or references to circuit diagrams).

Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
© Copyright 2004-2010 ABB. All rights reserved.

Controller hardware option manual

Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.

3HAC022032-001 Revision: H 9
Product documentation, M2004

Product documentation, M2004

Categories for manipulator documentation

The manipulator documentation is divided into a number of categories. This listing is based
on the type of information in the documents, regardless of whether the products are standard
or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed are valid for
M2004 manipulator systems.

Product manuals
All hardware, manipulators and controllers will be delivered with a Product manual that
contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation, electrical
connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals).
• Repair (descriptions of all recommended repair procedures including spare parts).
• Additional procedures, if any (calibration, decommissioning).
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards).
• Parts list.
• Foldouts or exploded views.
• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe the manipulator software in general and contain
relevant reference information.

© Copyright 2004-2010 ABB. All rights reserved.

• RAPID Overview: An overview of the RAPID programming language.
• RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions, and data types.
• RAPID Kernel: A formal description of the RAPID programming language.
• System parameters: Description of system parameters and configuration workflows.

Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, CD with PC software).
• How to use the application.
• Examples of how to use the application.
Continues on next page
10 3HAC022032-001 Revision: H
 Product documentation, M2004

Continued

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals are aimed
at those having first-hand operational contact with the product, that is production cell
operators, programmers, and trouble shooters.
The group of manuals includes:
• Emergency safety information
• General safety information
• Getting started, IRC5 and RobotStudio
• IRC5 with FlexPendant
• RobotStudio
• Introduction to RAPID
• Trouble shooting, for the controller and manipulator.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 11
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
manipulator/controller. The components or attachment points are marked with italic text in
the procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a procedure.

Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.

References to required equipment

The procedures often include references to equipment (spare parts, tools, etc.) required for the
different actions in the procedure. The equipment is marked with italic text in the procedures
and completed with a reference to the section where the equipment is listed with further
information, that is article number and dimensions.
The designation in the procedure for the component or attachment point corresponds to the
designation in the referenced list.
The table below shows an example of a reference to a list of required equipment from a step
in a procedure.

Action Note/Illustration

© Copyright 2004-2010 ABB. All rights reserved.

3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.

Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in the chapter Safety on page 13.

12 3HAC022032-001 Revision: H
 1 Safety
1.1. Introduction to safety information

1 Safety
1.1. Introduction to safety information

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 General safety
information on page 14.
• Specific safety information, pointed out in the procedures. How to avoid and eliminate
the danger is either described directly in the procedure, or in specific instructions in
the section Safety related instructions on page 32.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 13
1 Safety
1.2.1. Safety in the manipulator system

1.2 General safety information

1.2.1. Safety in the manipulator system

Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment that can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the
manipulator is installed.
The users of ABB industrial manipulators are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the safety devices
necessary to protect people working with the manipulator system are designed and installed
correctly. Personnel working with manipulators must be familiar with the operation and
handling of the industrial manipulator as described in the applicable documents, for example:
• User’s Guide - S4Cplus (M2000)
• Operating manual - IRC5 with FlexPendant
• Product manual

Connection of external safety devices

Apart from the built-in safety functions, the manipulator is also supplied with an interface for
the connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the manipulator.

Limitation of liability
Any information given in this manual regarding safety must not be construed as a warranty
by ABB that the industrial manipulator will not cause injury or damage even if all safety
instructions are complied with.

Related information © Copyright 2004-2010 ABB. All rights reserved.

Type of information Detailed in document Section

Installation of safety Product manual for the Installation and commissioning
devices manipulator
Changing operating User´s Guide - S4Cplus Start-up
modes (RobotWare 4.0) Operating modes
Operating manual - IRC5 with
FlexPendant
Restricting the working Product manual for the Installation and commissioning
space manipulator

14 3HAC022032-001 Revision: H
 1 Safety
1.2.2.1. Safety risks during installation and service work on manipulators

1.2.2. Safety risks

1.2.2.1. Safety risks during installation and service work on manipulators

Overview
This section includes information on general safety risks to be considered when performing
installation and service work on the manipulator.

General risks during installation and service

• The instructions in the Product manual in the chapter Installation and commissioning
must always be followed.
• Emergency stop buttons must be positioned in easily accessible places so that the
manipulator can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are available for
the installation in question.
• Those who install the manipulator must have the appropriate training for the
equipment in question and in any safety matters associated with it.

Nation/region specific regulations

To prevent injuries and damage during the installation of the manipulator, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.

Non-voltage related risks

• Safety zones, which must be crossed before admittance, must be set up in front of the
manipulator's working space. Light beams or sensitive mats are suitable devices.
• Turntables or the like should be used to keep the operator out of the manipulator's
working space.
• The axes are affected by the force of gravity when the brakes are released. In addition
© Copyright 2004-2010 ABB. All rights reserved.

to the risk of being hit by moving manipulator parts, there is a risk of being crushed
by the parallel arm (if there is one).
• Energy stored in the manipulator for the purpose of counterbalancing certain axes may
be released if the manipulator, or parts thereof, are dismantled.
• When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored heat energy in the controller.
• Never use the manipulator as a ladder, that is, do not climb on the manipulator motors
or other parts during service work. There is a serious risk of slipping because of the
high temperature of the motors or oil spills that can occur on the manipulator.

To be observed by the supplier of the complete system

• The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.
Continues on next page
3HAC022032-001 Revision: H 15
1 Safety
1.2.2.1. Safety risks during installation and service work on manipulators

Continued

Complete manipulator

Safety risk Description

Hot components!

CAUTION!
Motors and gears are HOT after running the manipulator!
Touching motors and gears may result in burns!
With a higher environment temperature, more surfaces on
the manipulator will get HOT and may also result in burns.
Removed parts may result in
collapse of manipulator!

WARNING!
Take any necessary measures to ensure that the
manipulator does not collapse as parts are removed, e.g.
secure the lower arm with fixtures if removing motor, axis
2.

Cabling

Safety risk Description

Cable packs are sensitive to
mechanical damage!

CAUTION!
The cable packs are sensitive to mechanical damage!
They must be handled with care, especially the
connectors, in order to avoid damaging them!

Gearboxes and motors

Safety risk Description

© Copyright 2004-2010 ABB. All rights reserved.

Gears may be damaged if
excessive force is used!

CAUTION!
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!

16 3HAC022032-001 Revision: H
 1 Safety
1.2.2.2. CAUTION - Hot parts may cause burns!

1.2.2.2. CAUTION - Hot parts may cause burns!

Description
During normal operation, many manipulator parts become hot, especially the drive motors
and gears. Sometimes areas around these parts also become hot. Touching these may cause
burns of various severity.
Because of a higher environment temperature, more surfaces on the manipulator get hot and
may result in burns.

Elimination
The instructions below detail how to avoid the dangers specified above:

Action Info
1. Always use your hand, at some distance, to feel if heat is
radiating from the potentially hot component before
actually touching it.
2. Wait until the potentially hot component has cooled if it is
to be removed or handled in any other way.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 17
1 Safety
1.2.2.3. Safety risks related to tools/workpieces

1.2.2.3. 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).

Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance to the controller.
CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.

© Copyright 2004-2010 ABB. All rights reserved.

18 3HAC022032-001 Revision: H
 1 Safety
1.2.2.4. Safety risks related to pneumatic/hydraulic systems

1.2.2.4. Safety risks related to pneumatic/hydraulic systems

General
Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy
• Residual energy can be present in these systems. After shutdown, particular care must
be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.

Safe design
• Gravity may cause any parts or objects held by these systems to drop.
• Dump valves should be used in case of emergency.
• Shot bolts should be used to prevent tools, etc., from falling due to gravity.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 19
1 Safety
1.2.2.5. Safety risks during operational disturbances

1.2.2.5. Safety risks during operational disturbances

General
• The industrial manipulator is a flexible tool that can be used in many different
industrial applications.
• All work must be carried out professionally and in accordance with the applicable
safety regulations.
• Care must be taken at all times.

Qualified personnel
Corrective maintenance must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.

Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other than those
associated with regular operation. Such an interruption may have to be rectified manually.

© Copyright 2004-2010 ABB. All rights reserved.

20 3HAC022032-001 Revision: H
 1 Safety
1.2.2.6. Risks associated with live electric parts

1.2.2.6. Risks associated with live electric parts

Voltage related risks, general

• Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
• The mains supply to the robot must be connected in such a way that it can be turned
off from outside the robot’s working space.

Voltage related risks, controller S4Cplus

A danger of high voltage is associated with the following parts:
• Be aware of stored electrical energy (DC link) in the controller.
• Units inside the controller, e.g. I/O modules, can be supplied with power from an
external source.
• The mains supply/mains switch
• The power unit
• The power supply unit for the computer system (230 VAC)
• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
• The drive unit (700 VDC)
• The service outlets (115/230 VAC)
• The power supply unit for tools, or special power supply units for the machining
process.
• The external voltage connected to the control cabinet remains live even when the robot
is disconnected from the mains.
• Additional connections
© Copyright 2004-2010 ABB. All rights reserved.

Continues on next page

3HAC022032-001 Revision: H 21
1 Safety
1.2.2.6. 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.
• Units such as I/O modules, can be supplied with power from an external source.
• The mains supply/mains switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
• The drive unit (700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• The power supply unit for additional tools, or special power supply units for the
machining process.
• The power supply unit for additional tools.
• The external voltage connected to the controller remains live even when the robot is
disconnected from the mains.
• Additional connections.

Voltage related risks, manipulator

A danger of high voltage is associated with the manipulator in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max. 230 VAC, see the
chapter Installation and commissioning in the Product manual).

Voltage related risks, tools, material handling devices, etc. © Copyright 2004-2010 ABB. All rights reserved.
Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be
damaged.

22 3HAC022032-001 Revision: H
 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 manipulator to ensure safe manipulator installation and
operation.

Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the manipulator is dropped or released at maximum speed. Determine the
maximum speed from the maximum velocities of the manipulator axes and from the position
at which the manipulator is working in the work cell (see the section Robot motion in the
Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 23
1 Safety
1.2.3.2. Fire extinguishing

1.2.3.2. Fire extinguishing

NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the manipulator
system (manipulator or controller)!

© Copyright 2004-2010 ABB. All rights reserved.

24 3HAC022032-001 Revision: H
 1 Safety
1.2.3.3. Emergency release of the manipulator’s arm

1.2.3.3. Emergency release of the manipulator’s arm

Description
In an emergency situation, any of the manipulator's axes may be released manually by
pushing the brake release buttons on the manipulator.
How to release the brakes is detailed in the section:
• Manually releasing the brakes on page 63.
The manipulator arm may be moved manually on smaller manipulator models, but larger
models may require using an overhead crane or similar equipment.

Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 25
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 is normally worn down. A test can 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. Run each manipulator axis to a position where the combined weight of the manipulator
arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the
controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.

© Copyright 2004-2010 ABB. All rights reserved.

26 3HAC022032-001 Revision: H
 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"

NOTE!
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".
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 27
1 Safety
1.2.3.6. Safe use of the FlexPendant

1.2.3.6. Safe use of the FlexPendant

NOTE!
The enabling device is a push-button located on the side of the FlexPendant which, when
pressed halfway in, takes the system to MOTORS ON. When the enabling device is released
or pushed all the way in, the manipulator is taken to the MOTORS OFF state.
To ensure safe use of the FlexPendant, the following must be implemented:
• The enabling device must never be rendered inoperational in any way.
• During programming and testing, the enabling device must be released as soon as
there is no need for the manipulator to move.
• The programmer must always bring the FlexPendant with him/her when entering the
manipulator's working space. This is to prevent anyone else taking control of the
manipulator without the programmer’s knowledge.

Enabling device
The enabling device is a manually operated, constant pressure push-button which, when
continuously activated in one position only, allows potentially hazardous functions but does
not initiate them. In any other position, hazardous functions are stopped safely.
The enabling device is of a specific type where you must press the push-button only half-way
to activate it. In the fully in and fully out positions, manipulator operation is impossible.

Hold-to-run function
The hold-to-run function allows movement when a button connected to the function is
actuated manually and immediately stops any movement when released. The hold-to-run
function can only be used in manual mode.
How to operate the hold-to-run function is described in Operating manual - IRC5 with
FlexPendant.

© Copyright 2004-2010 ABB. All rights reserved.

28 3HAC022032-001 Revision: H
 1 Safety
1.2.3.7. Work inside the manipulator's working range

1.2.3.7. Work inside the manipulator's working range

WARNING!
If work must be carried out within the manipulator’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 operational and to block operation from a computer link or
remote control panel.
• The manipulator’s speed is limited to max. 250 mm/s when the operating mode
selector is in the position Manual mode with reduced speed. This should be the normal
position when entering the working space. The position Manual mode with full speed
(100%) may only be used by trained personnel who are aware of the risks that this
entails.
• Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in
order not to get entangled with hair or clothing. Also be aware of any danger that may
be caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
• Test the motor brake on each axis, according to the section Brake testing on page 26.

WARNING!
NEVER, under any circumstances, stay beneath any of the manipulator’s axes! There is
always a risk that the manipulator will move unexpectedly when manipulator axes are moved
using the enabling device or during other work inside the manipulator’s working range.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 29
1 Safety
1.2.4.1. What is an emergency stop?

1.2.4. Safety stops

1.2.4.1. What is an emergency stop?

Definition of emergency stop

An emergency stop is a state that overrides any other manipulator control, disconnects drive
power from the manipulator motors, stops all moving parts and disconnects power from any
potentially dangerous functions controlled by the manipulator system.
An emergency stop state means that all power is disconnected from the manipulator except
for the manual brake release circuits. You must perform a recovery procedure, i.e, resetting
the emergency stop button and pressing the Motors On button, in order to return to normal
operation.
The manipulator system can be configured so that the emergency stop results in either:
• An uncontrolled stop, immediately stopping the manipulator actions by disconnecting
power from the motors.
• A controlled stop, stopping the manipulator actions with power available to the motors
so that the manipulator path can be maintained. When completed, power is
disconnected.
The default setting is uncontrolled stop. However, controlled stops are preferred since they
minimize extra, unnecessary wear on the manipulator and the actions needed to return the
manipulator system back to production. Please consult your plant or cell documentation to
see how your manipulator system is configured.
NOTE!
The emergency stop function may only be used for the purpose and under the conditions for
which it is intended.

NOTE!
The emergency stop function is intended for immediately stopping equipment in the event of

© Copyright 2004-2010 ABB. All rights reserved.

an emergency.

NOTE!
Emergency stop should not be used for normal program stops as this causes extra,
unnecessary wear on the manipulator. For how to perform normal program stops, see the
section Stopping programs inOperating manual - IRC5 with FlexPendant.

Classification of stops
The safety standards that regulate automation and manipulator equipment define categories
in which each type of stop applies:
If the stop is... ... then it is classified as...
uncontrolled category 0 (zero)
controlled category 1

Continues on next page

30 3HAC022032-001 Revision: H
 1 Safety
1.2.4.1. What is an emergency stop?

Continued

Emergency stop devices

In a manipulator system there are several emergency stop devices that can be operated in
order to achieve an emergency stop. There are emergency stop buttons available on the
FlexPendant and on the controller cabinet (on the Control Module on a Dual Cabinet
Controller). There can also be other types of emergency stops on your manipulator. Consult
your plant or cell documentation to see how your manipulator system is configured.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 31
1 Safety
1.3.1. Safety signals in the manual

1.3 Safety related instructions

1.3.1. Safety signals in the manual

Introduction to safety signals

This section specifies all dangers that can arise when doing the work described in this manual.
Each danger consists of:
• A caption specifying the danger level (DANGER, WARNING, or CAUTION) and the
type of danger.
• A brief description of what will happen if the operator/service personnel do not
eliminate the danger.
• An instruction on how to eliminate the danger to simplify doing the work.

Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.

Symbol Designation Significance

DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
danger
impact, fall from height, etc.
WARNING Warns that an accident may occur if the instructions
are not followed that can lead to serious injury,
possibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
warning
explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.

© Copyright 2004-2010 ABB. All rights reserved.

ELECTRICAL Warns for electrical hazards which could result in
SHOCK severe personal injury or death.

Electrical shock

CAUTION Warns that an accident may occur if the instructions

are not followed that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height, etc. Furthermore, it applies
caution to warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.

Continues on next page

32 3HAC022032-001 Revision: H
 1 Safety
1.3.1. Safety signals in the manual

Continued

Symbol Designation Significance

ELECTROSTATIC Warns for electrostatic hazards which could result in
DISCHARGE (ESD) severe damage to the product.

Electrostatic discharge
(ESD)

NOTE Describes important facts and conditions.

Note

TIP Describes where to find additional information or

how to do an operation in an easier way.

Tip
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 33
1 Safety
1.3.2. Safety symbols on the manipulator labels

1.3.2. Safety symbols on the manipulator labels

Introduction to labels
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbol are used in combinations on the labels, describing each specific warning. The
descriptions in this section are generic, the labels can contain additional information such as
values.

Types of labels
Both the manipulator and the controller are marked with several safety and information
labels, containing important information about the product. The information is useful for all
personnel handling the manipulator system, for example during installation, service, or
operation.
The safety labels are language independent, they only use graphics. See Symbols on safety
labels on page 34.
The information labels can contain information in text (English, German, and French).

Symbols on safety labels

Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply to
danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.

xx0900000812

Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.

© Copyright 2004-2010 ABB. All rights reserved.

It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping,
impact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
xx0900000811

Prohibition
Used in combinations with other symbols.

xx0900000839

Continues on next page

34 3HAC022032-001 Revision: H
 1 Safety
1.3.2. Safety symbols on the manipulator labels

Continued

Symbol Description
Product manual
Read the product manual for details.

xx0900000813

Before dismantling see product manual

xx0900000816

Do not dismantle
Dismantling this part can cause injury.

xx0900000815

Extended rotation
This axis has extended rotation (working area) compared to
standard.

xx0900000814

Brake release
Pressing this button will release the brakes. This means that the
manipulator arm can fall down.
© Copyright 2004-2010 ABB. All rights reserved.

xx0900000808

Tip risk when loosening bolts

The manipulator can tip over if the bolts are not securely
fastened.

xx0900000810

Crush
Risk for crush injuries.

xx0900000817

Continues on next page

3HAC022032-001 Revision: H 35
1 Safety
1.3.2. Safety symbols on the manipulator labels

Continued

Symbol Description
Heat
Risk of heat that can cause burns.

xx0900000818

Moving robot
The robot can move unexpectedly.

xx0900000819

Brake release buttons

xx0900000820

Lifting bolt

xx0900000821

Lifting of robot
© Copyright 2004-2010 ABB. All rights reserved.

xx0900000822

Oil
Can be used in combination with prohibition if oil is not allowed.

xx0900000823

Continues on next page

36 3HAC022032-001 Revision: H
 1 Safety
1.3.2. Safety symbols on the manipulator labels

Continued

Symbol Description
Mechanical stop

xx0900000824

Stored energy
Warns that this part contains stored energy.
Used in combination with Do not dismantle symbol.

xx0900000825

Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.

xx0900000826

Shut off with handle

Use the power switch on the controller.

xx0900000827
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 37
1 Safety
1.3.3. DANGER - Moving manipulators are potentially lethal!

1.3.3. DANGER - Moving manipulators are potentially lethal!

Description
Any moving manipulator is a potentially lethal machine.
When running, the manipulator may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may seriously
injure any personnel and/or damage any piece of equipment located within the working range
of the manipulator.

Elimination

Action Note
1. Before attempting to run the manipulator, Emergency stop equipment such as gates,
make sure all emergency stop equipment tread mats, light curtains, etc.
is correctly installed and connected.
2. Usually the hold-to-run function is active How to use the hold-to-run function is
only in manual full speed mode. To described in section How to use the hold-
increase safety it is also possible to to-run function in the Operating manual -
activate hold-to-run for manual reduced IRC5 with FlexPendant.
speed with a system parameter. How to use the hold-to-run control in
The hold-to-run function is used in manual RobotWare 4.0 is detailed in section The
mode, not in automatic mode. Teach Pendant unit in the User Guide.
3. Make sure no personnel are present within
the working range of the manipullator
before pressing the start button.

© Copyright 2004-2010 ABB. All rights reserved.

38 3HAC022032-001 Revision: H
 1 Safety
1.3.4. DANGER - First test run may cause injury or damage!

1.3.4. 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, such
as repair, installation, or maintenance.

Action
1. Remove all service tools and foreign objects from the robot and its working area!
2. Install all safety equipment properly!
3. Make sure all personnel are standing at a safe distance from the robot, that is out of its
reach behind safety fences, etc!
4. Pay special attention to the function of the part previously serviced!

Collision risks

CAUTION!
When programming the movements of the manipulator always check potential collision risks
before the first test run!
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 39
1 Safety
1.3.5. WARNING - The unit is sensitive to ESD!

1.3.5. WARNING - The unit is sensitive to ESD!

Description
ESD (electrostatic 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. This discharge may destroy sensitive electronics.

Elimination

Action Note
1. Use a wrist strap Wrist straps must be tested frequently to ensure
that they are not damaged and are operating
correctly.
2. Use an ESD protective floor mat. The mat must be grounded through a current-
limiting resistor.
3. Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.

Location of wrist strap button

The location of the wrist strap button is shown in the following illustration.

IRC5
The wrist strap button is located in the top right corner.

© Copyright 2004-2010 ABB. All rights reserved.

xx0500002171

A Wrist strap button

Continues on next page

40 3HAC022032-001 Revision: H
 1 Safety
1.3.5. WARNING - The unit is sensitive to ESD!

Continued

Panel Mounted Controller

xx0600003249

A Panel Mounted Control Module

B Panel Mounted Drive Module
C Wrist strap button NOTE! When not used, the wrist strap must always be
attached to the wrist strap button.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 41
1 Safety
1.3.6. WARNING - Safety risks during work with gearbox lubricants (oil or grease)

1.3.6. WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Description
When handling the gearbox lubricants, there is a risk of both personal injury and product
damage occurring! The following safety information must be regarded before performing any
work with lubricants in the gearboxes!

Warnings and elimination

Warning Description Elimination/Action

Changing and draining Make sure that protective gear
gearbox oil or grease may like goggles and gloves are
require handling hot lubricant always worn during this activity.
heated up to 90 °C!
-

Hot oil or grease!

When working with gearbox Make sure that protective gear
lubricant there is a risk of an like goggles and gloves are
allergic reaction! always worn.

Allergic reaction
When opening the oil or Open the plug carefully and
grease plug, there may be keep away from the opening. Do
pressure present in the not overfill the gearbox when
gearbox, causing lubricant to filling.
- spray from the opening!
Possible pressure
build-up in gearbox!
Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over- gearbox when filling it with oil or
pressure inside the gearbox grease!
which in turn may: After filling, check the correct
-
• damage seals and level.
Do not overfill! gaskets

© Copyright 2004-2010 ABB. All rights reserved.

• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the mix different types of oil unless
gearbox! specified in the instructions.
Always use the type of oil
-
specified by the manufacturer!
Do not mix types of oil!
Warm oil drains quicker than When changing gearbox oil, first
cold oil. run the robot for a time to heat
up the oil.

Heat up the oil!

Continues on next page

42 3HAC022032-001 Revision: H
 1 Safety
1.3.6. WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Continued

Warning Description Elimination/Action

The specified amount of oil or After refilling, check the lubricant
grease is based on the total level.
volume of the gearbox. When
changing the lubricant, the
- amount refilled may differ from
Specified amount the specified amount,
depends on drained depending on how much has
volume! previously been drained from
the gearbox.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 43
1 Safety
1.3.6. WARNING - Safety risks during work with gearbox lubricants (oil or grease)

© Copyright 2004-2010 ABB. All rights reserved.

44 3HAC022032-001 Revision: H
 2 Installation and commissioning
2.1. Introduction

2 Installation and commissioning

2.1. Introduction

General
This chapter contains information for installing the robot at the working site.
More detailed technical data can be found in the Product specification for the robot, such as:
• load diagram
• permitted extra loads (equipment)
• location of extra loads (equipment).

Safety information
Before any installation work is commenced, it is extremely important that all safety
information is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describes the danger and safety risks when performing the procedures. Read
the chapter Safety on page 13 before performing any installation work.

NOTE!
If the robot is connected to power, always make sure that the robot is connected to earth
before starting any installation work!
For more information see:
• Product manual - IRC5
• Product manual - IRC5 Compact
• Product manual - Panel Mounted Controller
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 45
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:
1. Make sure only qualified installation personnel conforming to all national and local codes
are allowed to perform the installation.
2. Make sure the robot is not damaged, by visually inspecting the robot and control cabinet
exterior.
3. Make sure the lifting device to be used is dimensioned to handle the weight of the robot
as specified in Weight, robot on page 46.
4. If the robot is not to be installed directly, it must be stored as described in Storage
conditions, robot on page 49.
5. Make sure the expected operating environment of the robot conforms to the specifications
as described in Operating conditions, robot on page 49.
6. Before taking the robot to the installation site, make sure the site conforms to Loads on
foundation, robot - all versions except IRB 4400/S and 4450S on page 47 and Protection
classes on page 49.
7. When the robot is not fastened to the floor and standing still, the robot is not stable in the
work area. Care must be taken when the arms are moved, so that the center of gravity is
not displaced which may cause the robot to tip over.
8. When these prerequisites are met, the robot may be taken to its installation site as
described in section On-site installation on page 57.
© Copyright 2004-2010 ABB. All rights reserved.
Weight, robot
The table below shows the weights of the different models:

Robot model Weight

IRB 4400/45 985 kg
IRB 4400/60 1040 kg
IRB 4400/L10 1040 kg
IRB 4400/L30 1060 kg
IRB 4400/S 1290 kg
IRB 4450S 1080 kg

L - Long arm
S - Shelf mounted robot

Continues on next page

46 3HAC022032-001 Revision: H
 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.
Note! These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
The rigidity of the foundation must be designed to minimize the affects of dynamic behaviour
on the robot. For optimal performance, the frequency for the foundation bearing the robot
must be higher than 30 Hz.
TuneServo can be used to adapt robot tuning for a non-optimal foundation.
Fxy and Mxy are vectors that can have any direction on the xy plane.
The illustration below shows the directions of the stress forces.

xx0300000254

Force Endurance load (in operation) Max. load (emergency stop)

Force xy ± 7500 N ± 9000 N
Force z +9500 ± 2000 N +9500 ± 3000 N
© Copyright 2004-2010 ABB. All rights reserved.

Torque xy ± 14000 Nm ± 16000 Nm

Torque z ± 2000 Nm ± 4000 Nm

Continues on next page

3HAC022032-001 Revision: H 47
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
Force z +9500 ±2000 N +9500 ±4000 N
Torque xy ±14000 Nm ±16000 Nm
Torque z ±2000 Nm ±4000 Nm

Loads on foundation, robot version IRB 4400/S

© Copyright 2004-2010 ABB. All rights reserved.

xx0300000255

Continues on next page

48 3HAC022032-001 Revision: H
 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 ± 9000 N
Force z 10 000 ± 5000 N 10 000 ± 7000 N
Torque x ± 8500 Nm ± 11 500 Nm
Torque y 3500 ± 14 000 Nm 3500 ± 11 500 Nm
Torque z ± 6500 Nm ± 11 000 Nm
Force x' 5000 ± 5000 N 5000 ± 7000 N
Force y' ± 6000 N ± 9000 N
Force z' 8500 ± 3000N 8500 ± 5500 N
Torque x' ± 9500 Nm ± 12 000 Nm
Torque y' 3500 ± 7500 Nm 3500 ± 11 500 Nm
Torque z' ± 2000 Nm ± 5500 Nm

Storage conditions, robot

The table below shows the allowed storage conditions for the robot:

Parameter Value
Min. ambient temperature -25° C
Max. ambient temperature +55° C
Max. ambient temperature (less than 24 hrs) +70° C
Max. ambient humidity 95% at constant temperature

Operating conditions, robot

The table below shows the allowed operating conditions for the robot:

Parameter Value
© Copyright 2004-2010 ABB. All rights reserved.

Min. ambient temperature +5° C

Max. ambient temperature +45° C
Max. ambient humidity 95% at constant temperature

Protection classes
The table below shows the protection class of the robot:

Robot Protection class

Standard version IP54
Foundry version IP67, steam washable

3HAC022032-001 Revision: H 49
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.
(mm) (mm) (degrees) (degrees)
0 1080 1720 0 0
1 887 2140 0 -30
2 708 836 0 65
3 1894 221 95 -60

© Copyright 2004-2010 ABB. All rights reserved.

4 570 -126 95 40
5 51 1554 -70 40
6 227 1210 -70 65

Robot motion
The table below specifies the types and ranges of the robot motion in every axis.

Location of motion Type of motion Range of movement

Axis 1 Rotation motion +165° to -165°
Axis 2 Arm motion +95° to -70°
Axis 3 Arm motion +65° to -60°
Axis 4 Wrist motion +200° to -200°
Axis 5 Bend motion +120° to -120°
Axis 6 Turn motion +400° to -400°

50 3HAC022032-001 Revision: H
 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) (degrees) (degrees)
B 1580 1720 0 0
C 1320 2390 0 -30
D 919 383 0 65
© Copyright 2004-2010 ABB. All rights reserved.

E 2303 -66 95 -60

F 180 -448 95 42
G 484 1804 -70 40
H 725 1254 -70 65

Robot motion
The table below specifies the types and ranges of the robot motion in every axis.

Location of motion Type of motion Range of movement

Axis 1 Rotation motion +165° to -165°
Axis 2 Arm motion +95° to -70°
Axis 3 Arm motion +65° to -60°
Axis 4 Wrist motion +200° to -200°
Axis 5 Bend motion +120° to -120°
Axis 6 Turn motion +400° to -400°

3HAC022032-001 Revision: H 51
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) (degrees) (degrees)
B 1700 1720 0 0
C 1424 2450 0 -30
D 970 274 0 65
E 2401 -135 95 -60
F 500 -786 95 23.6 © Copyright 2004-2010 ABB. All rights reserved.
G 588 1864 -70 40
H 845 1265 -70 65

Robot motion
The table below specifies the types and ranges of the robot motion in every axis.

Location of motion Type of motion Range of movement

Axis 1 Rotation motion +165° to -165°
Axis 2 Arm motion +95° to -70°
Axis 3 Arm motion +65° to -60°
Axis 4 Wrist motion +200° to -200°
Axis 5 Bend motion +120° to -120°
Axis 6 Turn motion +400° to -400°

52 3HAC022032-001 Revision: H
 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) (degrees) (degrees)
B 1580 1720 0 0
© Copyright 2004-2010 ABB. All rights reserved.

C 1320 2390 0 -30

D 919 383 0 65
E 2360 120 90 -60
F 239 -417 90 44
G 484 1804 -70 40
H 725 1254 -70 65

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3HAC022032-001 Revision: H 53
2 Installation and commissioning
2.2.5. Working range, IRB 4400/S

Continued

Robot motion
The table below specifies the types and ranges of the robot motion in every axis.

Location of motion Type of motion Range of movement

Axis 1 Rotation motion +135° to -135°
Axis 2 Arm motion +90° to -70°
Axis 3 Arm motion +65° to -60°
Axis 4 Wrist motion +200° to -200°
Axis 5 Bend motion +120° to -120°
Axis 6 Turn motion +400° to -400°

© Copyright 2004-2010 ABB. All rights reserved.

54 3HAC022032-001 Revision: H
 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:
Z
645

G
C H

B
D

390 530

570
E
1176
2400
xx0500002034

Positions in Position X Position Z Angle Axis 2 Angle Axis 3

illustration (mm) (mm) (degrees) (degrees)
B 2006 556 0 0
C 2190 978 0 -30
D 1101 239 0 65
E 1437 -1054 95 -60
F 294 -303 95 40
G 1195 1208 -70 40
© Copyright 2004-2010 ABB. All rights reserved.

H 1058 847 -70 65

Robot motion
The table below specifies the types and ranges of the robot motion in every axis.

Location of motion Type of motion Range of motion

Axis 1 Rotation motion +135° to -135°
Axis 2 Arm motion +90° to -70°
Axis 3 Arm motion +65° to -60°
Axis 4 Wrist motion +200° to -200°
Axis 5 Bend motion +120° to -120°
Axis 6 Turn motion +400° to -400°

3HAC022032-001 Revision: H 55
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.
Do not change the robot position before securing it to the foundation!

Stability
The figure below shows the robot in its shipping position, which also is the most stable
position.

© Copyright 2004-2010 ABB. All rights reserved.

xx0500002035

A Angle (degress specified for the different versions in the lifting instruction)
B Mechanical stop

WARNING!
The robot is likely to be mechanically unstable if not secured to the foundation!

56 3HAC022032-001 Revision: H
 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.

Required equipment

Equipment Art. no. Note

Crane Lifting capacity: 2100kg (max. load at 90°)
Round slings, 2 m Lifting capacity/sling: 1100kg
2 pcs for version IRB 4400/45, /60, /L10 and /L30
3 pcs for version IRB 4400/S if the erection position is to be 30°
3 pcs for version IRB 4450S
Lifting lugs Type: OBK 7-8

WARNING!
The manipulator weighs 1300 kg! All lifting equipment used must be dimensioned
accordingly!
WARNING!
Personnel must not, under any circumstances, be present under the suspended load!

CAUTION!
Failure to attach the straps correctly can cause the suspended load to tilt suddenly and cause
both personal injury and severe damage to the load.
© Copyright 2004-2010 ABB. All rights reserved.

Continues on next page

3HAC022032-001 Revision: H 57
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

A Angle (degrees specified for the different versions in the lifting instruction)

© Copyright 2004-2010 ABB. All rights reserved.

B 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).

Action Info
1. Release the brakes manually, to make it possible to Detailed in section Manually
alter the positions of the arms. releasing the brakes on page
63.
2. Move the robot to the calibration position.
3. Move the lower arm backwards to get balance, Angle (A) is shown in the figure
according to angle specified to the right. Lifting, robot version IRB 4400/
45, /60, /L10, /L30 on page 58.
• IRB 4400/45 and /L30: A:
-5°
• IRB 4400/60 and /L10: A:
0°

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58 3HAC022032-001 Revision: H
 2 Installation and commissioning
2.3.1. Lifting robot with round slings

Continued

Action Info
4. Attach the round slings to the special eye bolts on the Shown in the figure Lifting, robot
gearbox unit for axes 2 and 3 using lifting lugs. version IRB 4400/45, /60, /L10, /
L30 on page 58.
The roundsling and lifting lug
dimensions must comply with
the applicable standards
specified in Required
equipment on page 57.
5. Lift the robot to its installation site.
Make sure the slings do not rub against any sharp
edges!

Lifting robot version IRB 4400/S

The lifting equipment is attached to the robot as shown in the figure below.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000247

(1) Lifting angle for the robot: 0°

(2) Lifting angle for the robot: 30°
A Angle (degrees specified for the different versions in the lifting instruction)
B Axis 2
C Lifting lug

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3HAC022032-001 Revision: H 59
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
1. Release the brakes manually, to make it possible to Detailed in section Manually
alter the positions of the arms. releasing the brakes on page
63.
2. Move the robot to the calibration position.
3. Move the lower arm forward to get balance, according Angle (A) is shown in the figure
to angle specified to the right. Lifting robot version IRB 4400/S
on page 59.
If the robot liftangle is:
• 0°, then A=25°
• 30°, then A=0°
4. Attach the round slings to the special eye bolts on the Attachment points are shown in
gearbox unit for axes 2 and 3 using lifting lugs. the figure Lifting robot version
If the lifting angle of the robot is more than 0°, a round IRB 4400/S on page 59.
sling must also be attached to the rear of the robot. The roundsling and lifting lug
dimensions must comply with
the applicable standards
specified in Required
equipment on page 57.
5. Lift the robot to its installation site.
Make sure the slings do not rub against any sharp
edges!

© Copyright 2004-2010 ABB. All rights reserved.

Continues on next page

60 3HAC022032-001 Revision: H
 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

A Angle (degrees specified for the different versions in the lifting instruction)
B Mechanical stop

Lifting instruction, IRB4450S

The procedure below details how to lift the complete robot (IRB 4450S)
© Copyright 2004-2010 ABB. All rights reserved.

Action Info
1. Release the brakes manually, to make it possible to Detailed in section Manually
alter the positions of the arms. releasing the brakes on page
63.
2. Move the robot to its shipping position. See figure Lifting robot version
IRB 4450S on page 61
3. Move the robot to the calibration position.
4. Move the lower arm forward to get balance, according Angle (A) is shown in figure
to angle specified to the right. xx0500002035 above.
If the robot liftangle is:
0° then A=-20°
5. Attach the round slings to the special eye bolts on the Attachment points are shown in
gearbox unit for axes 2 and 3 using lifting lugs. Also figure xx0500002035 above.
attach the round slings around the mechanical stop The roundsling and lifting lug
as a third lifting point. dimensions must comply with
the applicable standards
specified in

Continues on next page

3HAC022032-001 Revision: H 61
2 Installation and commissioning
2.3.1. Lifting robot with round slings

Continued

Action Info
6. Lift the robot to its installation site.
Make sure the slings do not rub against any sharp
edges!
7. Danger!
When the robot is put down, before attachment to the
floor is done, the risk of tipping is big.

© Copyright 2004-2010 ABB. All rights reserved.

62 3HAC022032-001 Revision: H
 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 can be done in one of three ways:
• using the push-button when the robot is connected to the controller.
• using the push-button on the robot with an external power supply.
• using an external voltage supply directly on the respective brake.
DANGER!
When releasing the holding brakes with push-buttons, the robot must be properly attached!

DANGER!
When releasing the holding brakes, the robot axes may move very quickly and sometimes in
unexpected ways!
Make sure no personnel is near or beneath the robot arm!

Using the push-button when the robot is connected to the controller

The procedure details how to release the holding brakes with push-buttons, when the robot is
connected to the controller.

Action Note
1. The internal brake release unit is located at
the base of the robot.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000198

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2 Installation and commissioning
2.3.2. Manually releasing the brakes

Continued

Action Note
2. The brake release unit is equipped with six
buttons for controlling the axes brakes. The
buttons are numbered according to the
numbers of the axes.
3. Release the holding brake on a particular
axis by pressing the corresponding button
on the push-button unit and keeping it
depressed.
4. The brake will function again as soon as the
button is released.

Using the push-button on the robot with an external power supply

The procedure below details how to release the holding brakes with the push-buttons, when
the robot is not connected to the controller.

Action Note
1. Connect an external 24VDC power supply
to the connector R1.MP on the robot base,
as shown in the figure to the right.
Note! Be careful not to interchange the
24V and 0V pins.
If they are mixed up, damage can be
caused to the brake release unit and the
system board.

Danger!

DANGER!
Incorrect connections can cause all
brakes to be released simultaneously!

© Copyright 2004-2010 ABB. All rights reserved.

xx0300000200

Connect to connector R1.MP:

• 0V: pin B14 or B15
• +24V: pin B16

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64 3HAC022032-001 Revision: H
 2 Installation and commissioning
2.3.2. Manually releasing the brakes

Continued

Action Note
2. Release the holding brake on a particular The brake release unit is equipped with
axis by pressing the corresponding button six buttons for controlling the axes
on the push-button unit and keeping it brakes. The buttons are numbered
depressed. according to the numbers of the axes.
See the previous figure.
3. The brake will function again as soon as
the button is released.

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
1. Every axis has a holding brake built into the axis Make the connection to the
motor. This holding brake may be released by current motor according to
connecting 24VDC power supply directly to one of the the Circuit Diagram.
connectors in the motor. See the chapter Circuit
diagram.

Danger!

DANGER!
When power is connected directly to the brake
cable, the brake will be released immediately
when the power is switched on.
This may cause some unexpected robot
movements!
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 65
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.

Securing parts/fact Dimension/art. no. Amount/Note

Securing screws, oiled M20 3 pcs
Washers Thickness: 3 mm 3 pcs
Outer diameter: 36 mm
Inner diameter: 21 mm
Guide sleeves 2151 0024-169 2 pcs
Added to the rear bolt holes,
to allow the same robot to be
re-mounted without program
adjustments.
Tightening torque 350 - 400 Nm Oiled screws
Level surface requirements

xx0300000251

© Copyright 2004-2010 ABB. All rights reserved.

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66 3HAC022032-001 Revision: H
 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

A Rear bolt holes

B Center line, axis 1

Orienting and securing the robot

The procedure below details how to orient and secure the robot to the base plate after fitting
the plate to the foundation.
WARNING!
The manipulator weighs 1300 kg! All lifting equipment used must be dimensioned
accordingly!
© Copyright 2004-2010 ABB. All rights reserved.

Step Action Info/Illustration

1. Warning!
When the robot is put down, before attachment to the
floor is done, the risk of tipping is big, if not properly
secured.
2. Lift the robot. Detailed in section Lifting
robot with round slings on
page 57.
3. Move the robot to the vicinity of the installation site.
4. Fit two guide sleeves to the rear bolt holes in the Art. no. is specified in
base. Securing parts/facts on page
66.
Shown in the figure Hole
configuration and
dimensions on page 67.
5. Guide the robot gently using M20 screws while
lowering it into its mounting position.

Continues on next page

3HAC022032-001 Revision: H 67
2 Installation and commissioning
2.3.3. Orienting and securing the robot

Continued

Step Action Info/Illustration

6. Fit the securing screws and washers in the base Specified in Securing parts/
attachment holes. facts on page 66.
Attachment holes shown in
the figure Hole configuration
and dimensions on page 67.
7. When bolting a mounting plate or frame to a concrete
floor, follow the general instructions for expansion-
shell bolts.
The screw joint must be able to withstand the stress
loads defined in section Loads on foundation, robot -
all versions except IRB 4400/S and 4450S on page
47.

© Copyright 2004-2010 ABB. All rights reserved.

68 3HAC022032-001 Revision: H
 2 Installation and commissioning
2.3.4. Fitting equipment on robot

2.3.4. Fitting equipment on robot

General
The robot features mounting holes for additional equipment.
Access to any of the following mounting holes may be obstructed by any additional cabling,
equipment etc. fitted by the robot user. Make sure the required mounting holes are accessible
when planning the robot cell.
Never drill a hole in the 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.
The shaded area indicates the permitted positions (center of gravity) for any extra equipment
mounted in the holes.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000264

E Max. 15 kg
F M8 (2x), holes used if option 043 is chosen. Depth of thread: 9 mm
G M8 (3x) Depth of thread: 14 mm
H 571 mm for IRB 4400/45 and /60. 1071 mm for IRB 4400/S and /L30
I Max. 5 kg for IRB 4400/45 and /60 at max. handling weight and max. 5 kg
for IRB 4400/L30 and IRB 4450S at 25 kg handling weight
J 5 kg for IRB 4400/S and /L30 if the handling weight is max. 25 kg. If the
handling weight is 30 kg: 0 kg allowed!
K M6 (2x), tapped depth 12 mm

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3HAC022032-001 Revision: H 69
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.

xx0300000265

C Max. 15 kg
D M6 (2x) Depth of thread: 9 mm
E M8 (3x) Depth of thread: 14 mm
F Max. 2 kg

© Copyright 2004-2010 ABB. All rights reserved.

G M5 (2x)

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 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.

xx0300000266

A M8 (3x), R=2. Depth 16 mm (if option 623 is chosen, these holes are
occupied)
B Max. 35 kg for IRB 4400/45, /60, /L10, /L30 (0 kg for IRB 4400/S)

Fitting equipment on gearbox unit, IRB 4450S

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.
© Copyright 2004-2010 ABB. All rights reserved.

xx0500002136

A M8 (3x), R=2. Depth 16 mm (if option 623 is chosen, these holes

are occupied)
B Max. 35 kg for IRB 4450S

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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
IRB 4400/L10.

© Copyright 2004-2010 ABB. All rights reserved.

xx0300000268

C The hole can go through

72 3HAC022032-001 Revision: H
 2 Installation and commissioning
2.3.5. Loads

2.3.5. Loads

General
Any loads mounted on the robot must be defined correctly and carefully (with regard to the
position of center of gravity and mass moments of inertia) in order to avoid jolting
movements and overloading motors, gears and structure.
CAUTION!
Incorrectly defined loads may result in operational stops or major damage to the robot.

References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the
Product Specification. The loads must also be defined in the software as detailed in User's
Guide(RobotWare 4.0)Operating manual IRC5 with FlexPendant.

Stop time and braking distances

Robot motor brake performance depends on any loads attached. For information about brake
performance, see Product Specification for the robot.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 73
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:
• Axis 1, hardware (mechanical stop) and software (signal from adjustable position
switch)
• Axis 2, hardware (mechanical stop)
• Axis 3, software (signal from limit switch)
This section describes how to install hardware that restricts the working range.
Note! Adjustments must also be made in the robot configuration software (system
parameters). References to relevant manuals are included in the installation procedures.

© Copyright 2004-2010 ABB. All rights reserved.

74 3HAC022032-001 Revision: H
 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.

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Mechanical stop, axis 1 3HAB3833-1 Includes 2 additional stop lugs,
8 attachment screws, 8 plain
washers and a label
Attachment screw 9ADA183-71 4 pcs/lug, included in
3HAB3833-1
M12x60
Washer 9ADA312-9 4 pcs/lug, included in
3HAB3833-1
13x24x2.5
Standard toolkit 3HAC17594-1 The content is defined in the
section Standard toolkit on
page 275.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the step-
by-step instructions
below.
© Copyright 2004-2010 ABB. All rights reserved.

Continues on next page

3HAC022032-001 Revision: H 75
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.

xx0300000258

B Mechanical stop lugs

C Attachment screw and washer
D Stop pin

© Copyright 2004-2010 ABB. All rights reserved.

E Max. working range with stop lugs (250°)
F Min. working range with stop lugs (127°)

Fitting, mechancial stop axis 1

How to fit the additional mechanical stop to the base is described in the procedure.
Mounting instructions are also supplied with the kit.

Action Note
1. Determine the position of the stop lugsand mark the See the figure Additional stops
hole positions on the base. on page 76 for guidance.
2. Drill Ø10.2 mm to a maximum depth of 45 mm and tap
with M12 thread. Min. thread depth 35 mm.
3. Fit the stop lugs firmly with attachment screws and Specified in Required equipment
washers according to the figure Additional stops on on page 75.
page 76. M12x60, tightening torque: 82
Nm, oil lubrication.

76 3HAC022032-001 Revision: H
 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. Note that the system parameter configuration must also be adjusted (Upper joint
bound and Lower joint bound for the type Arm in the topic Motion).

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Mechanical stop, axis 2 3HAC4225-1 Includes spacers, dampers,
attachment screws and nuts.
Spacer (damper) 3HAB9185-1
Spacer 3HAC3962-1
Standard toolkit 3HAC17594-1 The content is defined in the
section Standard toolkit on
page 275.
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.
© Copyright 2004-2010 ABB. All rights reserved.

Continues on next page

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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.

© Copyright 2004-2010 ABB. All rights reserved.

xx0300000260

A View A of the lower arm

B View B of the lower arm
C Cut of the mech stop attachment
D Spacer
E Attachment screw, spacer (+nut)
F Damper
G Attachment screw, damper (+nut)

Continues on next page

78 3HAC022032-001 Revision: H
 2 Installation and commissioning
2.4.3. Mechanically restricting the working range of axis 2

Continued

Working range
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°

Working range Damper, qty Spacer, qty

+95° / -70° - -
+95° / -40° - 2
+95° / -10° 2 2
+65° / -70° 2 -
+65° / -40° 2 2
+65° / -10° 4 2
+35° / -70° 4 -
+35° / -40° 4 2
+35° / -10° 6 2
+5° / -70° (not applicable on IRB 4400/S) 6 -
+5° / -40° (not applicable on IRB 4400/S) 6 2
+5° / -10° (not applicable on IRB 4400/S) 8 2

• Each damper is fitted with: 2 attachment screws and 2 hexagon nuts.

• Each spacer is fitted with: 1 attachment screw and 1 hexagon nut.

Fitting, mechancial stop axis 2

The procedure below details how to fit the additional mechanical stop to the lower arm and
the gearbox unit.
Mounting instructions are also supplied with the kit.

Action Info/Illustration
1. Determine the working range restriction. See Working range on page 79.
© Copyright 2004-2010 ABB. All rights reserved.

2. Fit both the spacers to either side of the gearbox unit, Shown in the figure Additional
with the attachment screws and nuts, spacer. stops on page 78.
Art. no. is specified in Required
equipment on page 77.
Attachment screw: 1 pc/spacer,
M16x70. Tightening torque: 156
Nm.
3. Fit the dampers to both sides of the lower arm with the Shown in the figure Additional
attachment screws and nuts, damper. stops on page 78.
Art. no. is specified in Required
equipment on page 77.
Attachment screws: 2 pcs/
damper, M10x60. Tightening
torque: 49 Nm.

3HAC022032-001 Revision: H 79
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. The system parameter configuration must
also be updated.

Electrical stop
All the separate parts of the electrical stop are fitted to axis 3 as shown in the figure below.

xx0300000262

A Sealing with dust lip (3HAB 3701-14)

B Stud (2122 2012-867)
C All screws are locked with locking liquid

© Copyright 2004-2010 ABB. All rights reserved.

D Tap (3HAB 3798-1)
E Hexagon nut (9ADA 267-7)
F Disc (3HAB 3799-1)
G Screw (9ADA 618-44)
H Cam (3HAB 3800-1)
I Bracket (3HAB 8400-1)
J Limit switch complete (3HAB 8312-1)
K Screw (9ADA 629-50)
L Attachment screw (9ADA 183-35)
M Retaining ring (9ABA 135-18), reducing coupling (2686 015-3), washer (2152 398-3)

Continues on next page

80 3HAC022032-001 Revision: H
 2 Installation and commissioning
2.4.4. Electrically restricting the working range of axis 3

Continued

Required equipment

Equipment, etc. Art. no. Note

Electrical stop, axis 3 3HAB3795-1 Includes all spare parts shown in the
figure Electrical stop on page 80.
Locking liquid Loctite 243
Standard toolkit 3HAC17594-1 The content is defined in the section
Standard toolkit on page 275.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.
Circuit diagrams See the chapter Circuit diagram.

Fitting, electrical stop axis 3

The procedure below details how to fit the electrical stop to axis 3.
Mounting instructions are also supplied with the kit.

Action Info/Illustration
1. Remove the covers (A) from axis 3.

xx0300000263
© Copyright 2004-2010 ABB. All rights reserved.

2. All screws are locked with locking liquid, when fitted. Specified in Required equipment
on page 81.
3. Fit the electrical stop according to the figure Electrical
stop on page 80.
4. Adjust the software working range limitations (system The system parameters that
parameter configuration) to correspond to the must be changed (Upper joint
mechanical limitations. bound and Lower joint bound)
are described in Technical
reference manual - System
parameters.

3HAC022032-001 Revision: H 81
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.
Follow the procedure below to dismantle the mechanical stop.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

Location of mechanical stop, axis 4

The mechanical stop of axis 4 is located as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0300000176 © Copyright 2004-2010 ABB. All rights reserved.

A Mechanical stop axis 4

B Damper axis 4
C Attachment screws, mechanical stop

Continues on next page

82 3HAC022032-001 Revision: H
 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.
WARNING!
When the damper is removed from axis 4, the axis does not have a mechanical stop! If the
robot is provided with cabling on the upper arm, the cabling can be damaged when the
function Resetting the work area for an axis is used, or if the robot is jogged uncalibrated.

Action Info/Illustration
1.

DANGER!
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.
2. Loosen the attachment screws, mech stop and Shown in the figure Location of
remove the mechanical stop, axis 4. mechanical stop, axis 4 on page
82.
3. Slowly rotate axis 4 until the damper is visible through
the hole.
4. Remove the damper.
5. Refit the mechanical stop to the axis 4 with its 4 pcs, M8x16. Tightening torque:
attachment screws. 24 Nm.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 83
2 Installation and commissioning
2.5.1. Customer connection on robot

2.5 Electrical connections

2.5.1. Customer connection on robot

Location of customer connection

For the 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.
The customer connections are located on the robot as shown in the figure.

xx0300000270

A R1.CP, R1.CS, Air R1/4"

B R2.CP, R2.CS, Air R1/4"
C R3.CP, R3.CS, Air R1/4"

Extra equipment connections

Connections to the:
• air hose (R1/4" ) is located on the rear part of the upper arm and at the base. Max. 8

© Copyright 2004-2010 ABB. All rights reserved.

bar. Inner hose diameter: 8 mm.
• signal cabling (option) is located on the front of the upper arm.
Number of signals: 23 (50V, 250mA), 10 (250V, 2A), one protective ground.

Continues on next page

84 3HAC022032-001 Revision: H
 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.

Connec-
Connector Art. no. Content
tion set
R1.CP/CS R1.CP/CS 3HAC12275-1 • socket for area of 0.14 - 0.5 mm2
(IRB 4400 • compression gland for cables,
Protection diameter 2 x 12 mm
Standard) • key pin
R1.CP/CS F R1.CP/CS 3HAC12276-1 • socket for area of 0.14 - 0.5 mm2
(IRB 4400 • compression gland for cables,
Protection diameters 10 mm and 12 mm
Foundry) • key pin
R2.CS/R3.CS R2.CS/ 3HAC12327-1 • pins for cable area of 0.13 - 0.25
R3.CS mm2
• reduction hose, bottled-shaped
• reduction hose, angled
R2.CP/R3.CP R2.CP/ 3HAC12326-1 • pins for cable area of 0.13 - 0.25
R3.CP mm2
• reduction hose, bottled-shaped
• reduction hose, angled
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 85
2 Installation and commissioning
2.5.2. Customer connections on upper arm

2.5.2. Customer connections on upper arm

Customer connections on upper arm

The figure shows the customer connections on the upper arm, including the optional signal
lamp that can be fitted to the armhouse.

xx0300000269

A R2.CP
B R2.CS
C Signal lamp (option)

© Copyright 2004-2010 ABB. All rights reserved.

D R3.H1 +, R3.H2 -

Power supply connections on upper arm

Customer Contact on robot

Customer Customer
base
Signal name Terminal Contact on
(cable between robot and con-
Controller Upper arm, R2
troller not supplied)
CPA XT6.1 R2.CP.A RI.CP/CS.A1
CPB XT6.2 R2.CP.B RI.CP/CS.B1
CPC XT6.3 R2.CP.C RI.CP/CS.C1
CPD XT6.4 R2.CP.D RI.CP/CS.D1
CPE XT6.5 R2.CP.E RI.CP/CS.A2
CPF XT6.6 R2.CP.F RI.CP/CS.B2
R2.CP.G (Earth) RI.CP/CSP Earth
XT6.H R2.CP.H (Key pin)
CPJ XT6.7 R2.CP.J RI.CP/CS.C2
Continues on next page
86 3HAC022032-001 Revision: H
 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)
CPK XT6.8 R2.CP.K RI.CP/CS.D2
CPL XT6.9 R2.CP.L RI.CP/CS.A3
CPM XT6.10 R2.CP.M RI.CP/CS.B3

Signal connections on upper arm

Customer Contact on robot

Customer Customer
base
Signal name Terminal Contact on
(cable between robot and con-
Controller Upper arm, R2
troller not supplied)
CSA XT5.1 R2.CS.A R1.CS/CP.B5
CSB XT5.2 R2.CS.B R1.CS/CP.C5
CSC XT5.3 R2.CS.C R1.CS/CP.D5
CSD XT5.4 R2.CS.D R1.CS/CP.A6
CSE XT5.5 R2.CS.E R1.CS/CP.B6
CSF XT5.6 R2.CS.F R1.CS/CP.C6
CSG XT5.7 R2.CS.G R1.CS/CP.D6
CSH XT5.8 R2.CS.H R1.CS/CP.A7
CSJ XT5.9 R2.CS.J R1.CS/CP.B7
CSK XT5.10 R2.CS.K R1.CS/CP.C7
CSL XT5.11 R2.CS.L R1.CS/CP.D7
CSM XT5.12 R2.CS.M R1.CS/CP.A8
CSN XT5.13 R2.CS.N R1.CS/CP.B8
CSP XT5.14 R2.CS.P R1.CS/CP.C8
CSR XT5.15 R2.CS.R R1.CS/CP.D8
CSS XT5.16 R2.CS.S R1.CS/CP.A9
© Copyright 2004-2010 ABB. All rights reserved.

CST XT5.17 R2.CS.T R1.CS/CP.B9

CSU XT5.18 R2.CS.U R1.CS/CP.C9
CSV XT5.19 R2.CS.V R1.CS/CP.D9
CSW XT5.20 R2.CS.W R1.CS/CP.A10
CSX XT5.21 R2.CS.X R1.CS/CP.B10

3HAC022032-001 Revision: H 87
2 Installation and commissioning
2.6.1. Installation of IRB4400 in a water jet application

2.6 Additional installation (Foundry Prime)

2.6.1. Installation of IRB4400 in a water jet application

General
Robots delivered with the Foundry Prime protection are specially designed to work in water
jet cleaning cells with 100% humidity and alkaline detergent. To ensure that the protection
offers the best reliability, some measures are needed during installation of the robot according
to the procedures below.
NOTE!
For best reliability, it is also of highest importance that the special maintenance instructions
for the Foundry Prime robot are followed and documented.

Commissioning
• Never switch off the overpressure in motors and serial measurement compartment
during cooling down of robot after it has been switched off.
• When turning off an cleaning cell we recommend that the humid air inside a cell is
ventilated out, to avoid that the humid air is sucked into e.g. gearboxes due to the
raised vacuum when cooled down.

Environmental conditions
Humidity 100%
Washing detergent with pH <9.0
Washing detergent must contain rust inhibitor and 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. Following table details the air © Copyright 2004-2010 ABB. All rights reserved.
specification.

Dew point <+2°C at 6 bar

Solid particle size <5 microns
Oil content <1 ppm (1 mg/m3)
Pressure to robot 0.2-0.3 bar

WARNING!
If the pressurized air contains oil, it could result in a brake failure in the motors and cause the
robot arms to fall down, leding to personal injure or physical damage.
WARNING!
If the air pressure exceeds the specified, it could result in a brake failure in the motors and
cause the robot arms to fall down, leding to personal injure or physical damage.

Continues on next page

88 3HAC022032-001 Revision: H
 2 Installation and commissioning
2.6.1. Installation of IRB4400 in a water jet application

Continued

NOTE!
To secure sufficient air pressure, it is recommended to use a pressure sensor.

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.
WARNING!
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.

Action Note/Illustration
1. Connect a compressed air hose to air
connector on robot base, see illustration.

xx0600003107

• A: connection to motors
2. Protect the screws on the Harting Do this when the controller cables are
connectors on the robot base from connected.
corrosion with Mercasol 3106.
3. Pressurize the robot. See Air specification for pressurizing of
robot on page 88 for correct pressure.
4. Inspect the air system. See Inspection of air hoses (Foundry
Prime) on page 99.
© Copyright 2004-2010 ABB. All rights reserved.

Protecting from high pressure water

WARNING!
No part of the robot should be exposed to direct high pressure jet of water. The sealings
between the moving parts on the wrist should not be exposed to direct or rebounding high-
pressure jet of water.

Continues on next page

3HAC022032-001 Revision: H 89
2 Installation and commissioning
2.6.1. Installation of IRB4400 in a water jet application

Continued

Protecting the wrist joints

The sealings between the moving parts on the wrist should not be exposed to direct high-
pressure water. We recommend that the gripper include a shield that prevents direct water
flush on the sealing surfaces of the wrist. The sealings are pointed out in the illustration
below.

A
B

C
xx0600003108

A Axis 5, bearing support side

B Axis 5, bearing gear side
C 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.

Action Note/Illustration
1. After mounting the tool, clean the following surfaces
from grease:
• the visible surface (not painted)
• the rear end of the screw holes and end of
screws. © Copyright 2004-2010 ABB. All rights reserved.

B
A
xx0600003109

• screw holes and

screws
• unpainted surface
2. Protect these surfaces with Mercasol 3106.
3. Before running the robot in a water jet cleaning cell: Inspection of air hoses
• perform a inspection of the pressure in motors (Foundry Prime) on page 99
and SMB cavity.

90 3HAC022032-001 Revision: H
 2 Installation and commissioning
2.6.2. Commissioning (Foundry Prime)

2.6.2. Commissioning (Foundry Prime)

General
The following should be taken in consideration when running a robot in a water jet
application cell:
CAUTION!
Never switch off the overpressure in motors and serial measurement compartment during
cooling down of robot after it has been switched off.
NOTE!
To reduce the risk for corrosion due to condensation in gearboxes, it is recommendable that
the robot is running with high speed on each axes at least on one occasion each hour. This is
to lubricate the gearbox cavities.
NOTE!
When turning off a cleaning cell we recommend that the humid air is ventilated out from the
cell, to avoid that the humid air is sucked into gearboxes for example, due to the raised
vacuum when cooled down.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 91
2 Installation and commissioning
2.7.1. Additional installation procedure, Clean room

2.7 Making robot ready for operation, Clean room

2.7.1. Additional installation procedure, Clean room

General
Clean room robots are specially designed to work in a clean room environment.
Clean room robots are designed in order to prevent from particle emission from the robot. For
example is maintenance work possible to perform without cracking the paint. The robot is
painted with four layers of polyurethane paint. The last layer being a varnish over labels in
order to simlify cleaning.
Clean room parts being replaced must be replaced with parts designed for use in Clean room
environments.

Clean room class 5

Particle emission from the robot fulfill Clean room class 5 standard according to DIN EN ISO
14644-1.

Preparations before commissioning a Clean room robot

During transport and handling of a Clean room robot, it is likely that the robot has been
contaminated with particles of different kinds. Therefore the robot must be minutely cleaned
before installation.

© Copyright 2004-2010 ABB. All rights reserved.

92 3HAC022032-001 Revision: H
 3 Maintenance
3.1. Introduction

3 Maintenance
3.1. Introduction

Structure of this chapter

This chapter details all maintenance activities recommended for the manipulator.
It is based on the maintenance schedule located at the beginning of the chapter. The schedule
contains information about required maintenance activities including intervals and refers to
procedures for the activities.
Each procedure contains all the information required to perform the activity, that is, required
tools and materials.
The procedures are gathered in different sections and divided according to the maintenance
activity.

Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describes the danger and safety risks when performing the procedures. Read
the chapter Safety on page 13 before performing any service work.
NOTE!
If the robot is connected to power, always make sure that the robot is connected to earth
before starting any maintenance work!
For more information see:
• Product manual - IRC5
• Product manual - IRC5 Compact
• Product manual - Panel Mounted Controller
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 93
3 Maintenance
3.2.1. Specification of maintenance intervals

3.2 Maintenance schedule

3.2.1. Specification of maintenance intervals

Introduction
The intervals are specified in different ways depending on the type of maintenance activity to
be carried out and the working conditions of the manipulator:
• Calendar time: specified in months regardless of whether the manipulator system is
run or not
• Operating time: specified in operating hours. More frequent running of the
manipulator means more frequent maintenance activities.

© Copyright 2004-2010 ABB. All rights reserved.

94 3HAC022032-001 Revision: H
 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.

Activities and intervals

The table below specifies the required maintenance activities and intervals.

Maintenance
Equipment Interval Detailed in section
activity
Replacement Battery pack, Battery low Replacement of battery pack,
measuring system alert 1) measuring system on page 102
Replacement Signal cabling, upper 12,000 hrs Replacement of signal cabling,
arm (option 042) upper arm (option 042) on page
161
Inspection Mechanical stop, Regularly 3) Inspection of mechanical stop, axis
axis 1 1 on page 97
Change Oil, gearbox axis 4 12,000 hrs 2) Oil change, gearbox axis 4 on page
111
Change Oil, gearbox axes 5 12,000 hrs 2) • Oil change, gearbox axis 5
and 6 and 6 (all robot versions
except IRB 4400/L10) on
page 114
• Oil change, gearbox axis 5
and 6 (IRB 4400/L10 only)
on page 117

1. Battery low alert (38213 Battery charge low) is displayed when remaining backup
© Copyright 2004-2010 ABB. All rights reserved.

capacity (robot powered off) is less than 2 months. Typical lifetime of a new battery
is 36 months if the robot is powered off 2 days/week or 18 months if the robot is
powered off 16 h/day. The lifetime can be extended (approx. 3 times) for longer
production breaks by a battery shutdown service routine. See Operating manual -
IRC5 with FlexPendant for instructions..
2. The gearboxes are lubricated for life, which corresponds to 40,000 hours of operation
if the robot is operating with an ambient temperature of less than 40° C. If the
temperature is higher, the oil should be changed!
3. Must be replaced if bent!

Continues on next page

3HAC022032-001 Revision: H 95
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.

Maintenance
Equipment Interval Detailed in section
activity
Inspection Cable harness 6 months
Replacement If required 4) Replacement of cable
harness, axes 1-3 on page
127 or Replacement of
cable harness, axes 4-6 on
page 132
Inspection Mechanical stop, Regularly 3) Inspection of mechanical
axis 1 stop, axis 1 on page 97
Inspection Air hoses 6 months Inspection of air hoses
(Foundry Prime) on page
99
Inspection Wrist rust protection 6 mths Protecting the wrist flange
from corrosion on page 90
Inspection Surface treatment 6 months 5) Inspection of surface
treatment (Foundry Prime)
on page 101
Changing Gear oil axes 1-6 6,000 hrs 2) Change and checking of oil
on page 106
Replacement Battery pack, Battery low alert 1) Replacement of battery
measuring system pack, measuring system on
page 102

1. Battery low alert (38213 Battery charge low) is displayed when remaining backup
capacity (robot powered off) is less than 2 months. Typical lifetime of a new battery
is 36 months if the robot is powered off 2 days/week or 18 months if the robot is
powered off 16 h/day. The lifetime can be extended (approx. 3 times) for longer

© Copyright 2004-2010 ABB. All rights reserved.

production breaks by a battery shutdown service routine. See Operating manual -
IRC5 with FlexPendant for instructions..
2. The gearboxes are lubricated for life, which corresponds to 40,000 hours of operation
if the robot is operating with an ambient temperature of less than 40° C. If the
temperature is higher, the oil should be changed!
3. Must be replaced if bent!
4. Parts that need to be changed according to the maintenance schedule are not covered
by warranty.
5. Damage to painted surfaces must be repaired as soon as possible to avoid corrosion.

96 3HAC022032-001 Revision: H
 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.

xx0300000182

A Mechanical stop pin, axis 1

B Set screw

Required equipment

Equipment, etc. Spare part no. Note

Mechanical stop, axis 1 3HAB 3647-1
Standard toolkit The content is defined in the
section Standard toolkit on
page 275.
Other tools and procedures may be These procedures include
required. See references to these references to the tools
© Copyright 2004-2010 ABB. All rights reserved.

procedures in the step-by-step required.

instructions below.

Continues on next page

3HAC022032-001 Revision: H 97
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
WARNING!
If the mechanical stop has been deformed after a hard collision, it must be replaced!

Action Info
1.

DANGER!
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.
2. Check regularly that the stop pin is not bent or
damaged in any other way.
3. Removal/refitting of the
mechanical stop is detailed in
section Replacement of
NOTE! mechanical stop pin, axis 1 on
If the mechanical stop pin has been deformed or page 197.
damaged, it must be replaced by a new one!
4. Also check that the stop pin is properly attached.

© Copyright 2004-2010 ABB. All rights reserved.

98 3HAC022032-001 Revision: H
 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 months.

Required equipment

Equipment, etc. Art. no.

Leak detection spray -
Pressure gauge -
Cut off valve -

Procedure
For this test it is recommended that the air supply to the robot has a pressure gauge and a cut-
off valve connected.

Action Note
1. Apply compressed air to the air Recommended pressure:
connector on robot base, and 0.2-0.3 bar
raise the pressure with the knob
until the correct value is shown on
the pressure gauge.

B
xx0600003341

• A: Air Connection
© Copyright 2004-2010 ABB. All rights reserved.

• B: Pressure gauge
• C: Cut off valve
2. Close the cut off valve. It should take at least 5 seconds for the pressure to
reach 0 bar.
3. The time is < 5 seconds:
• If the answer is YES:
Localize the leakage by
following the procedures
below.
• If the anser is NO: The
system is OK. Remove the
leak testing equipment.
4. Pressurize by opening the cut off
valve.
5. Spray suspected leak areas with
leak detection spray.
Bubbles indicate a leak.

Continues on next page

3HAC022032-001 Revision: H 99
3 Maintenance
3.3.2. Inspection of air hoses (Foundry Prime)

Continued

Action Note
6. When the leak is localized: correct
the leak.

© Copyright 2004-2010 ABB. All rights reserved.

100 3HAC022032-001 Revision: H

 3 Maintenance
3.3.3. Inspection of surface treatment (Foundry Prime)

3.3.3. Inspection of surface treatment (Foundry Prime)

Introduction to inspection of surface treatment

Damage to painted surfaces must be repaired as soon as possible to avoid corrosion. All
painted surfaces on the robot must be inspected.

Required equipment

Equipment, etc. Spare part no

Touch up paint Foundry Prime, orange 3HAC037052-001
Touch up paint Foundry Prime 2, grey 3HAC035355-001

Inspection and repair of surface treatment

Use this procedure to inspect the surface treatment on Foundry Prime robots.

Action Info
1. Inspect all painted surfaces for damages.
2. Repair damages as described in the instruction
included in the spare part kit.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 101

3 Maintenance
3.3.4. Replacement of battery pack, measuring system

3.3.4. Replacement of battery pack, measuring system

NOTE!
The SMB lithium battery lifetime can be extended significantly during a production break.
Activate sleep mode in IRC5 by a service routine that is described in Operating manual –
IRC5 with FlexPendant, chapter Battery shutdown service routine.

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

A Rear cover plate

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Battery pack 4944 026-4 Rechargeable nickel-
cadmium battery.
Battery pack 3HAC 16831-1 Lithium battery.
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in

© Copyright 2004-2010 ABB. All rights reserved.

the Product manual,
reference information.
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.

Continues on next page

102 3HAC022032-001 Revision: H
 3 Maintenance
3.3.4. 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.

Step Action Info/Illustration

1.

esd

WARNING!
The unit is sensitive to ESD. Before handling the unit
please read the safety information in the section
WARNING - The unit is sensitive to ESD! on page 40
2. Set the robot to the MOTORS OFF operating mode.
This way the robot does not need to be calibrated
after the battery change.
3. Remove the rear cover plate from the base. Shown in the figure Location
of battery pack on page 102.
4. Loosen the battery terminals from the serial
measuring board and cut the clasps that keep the
battery pack in place.
5. Remove the old battery pack.
6. Fit a new battery pack with two clasps and connect Part no. is specified in
the terminals to the serial measuring board. Required equipment on
page 102.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 103

3 Maintenance
3.3.5. Cleaning, robot

3.3.5. Cleaning, robot

WARNING!
Turn off all electrical power supplies to the manipulator before entering the manipulators
work space!

General
To secure high uptime it is important that the robot is cleaned regularly. The frequency of
cleaning depends on the environment that the robot is working in.
Depending on the protection of the robot, different methods of cleaning of the robot are
allowed. This section describes how to clean a robot with protection Standard, Foundry Plus
and Foundry Prime.
NOTE!
Always check the serial number sign for verification about the robot protection class.

Cleaning activities
This instruction specifies allowed cleaning methods for each protection class.

Standard Foundry Plus Foundry Prime

Cleaning method

Vacuum cleaner. Yes. Yes. Yes.

Wipe with cloth. Yes. With light Yes. With light Yes. With cleaning
cleaning detergent. cleaning detergent detergent approved
or spirit. by ABB, spirit or
isopropyl alcohol.

Rinse with water. Yes. It is highly Yes. It is highly Yes. It is highly

recommended that recommended that recommended that
water contains a rust water contains a water contains a rust
prevention solution rust prevention prevention solution.

© Copyright 2004-2010 ABB. All rights reserved.

and that the robot is solution.
dried afterwards.

High pressure water or No. Yes. It is highly Yes. It is highly

steam according to recommended that recommended that
chapter Cleaning with water and steam water and steam
water and steam below. contains rust contains rust
preventive, without preventive. If
cleaning cleaning detergents
detergents. are used they must
be approved by ABB
for Foundry Prime
robots.

Continues on next page

104 3HAC022032-001 Revision: H
 3 Maintenance
3.3.5. Cleaning, robot

Continued

Cleaning with water and steam

Cleaning methods that can be used for ABB robots with protection Standard, Foundry Plus,
Wash, Foundry Prime.
Equipment, etc. Note
Vacuum cleaner
Cloth with mild detergent
Water cleaner • Max. water pressure at the nozzel: 700 kN/m 2 (7
bar) (1)
• Fan jet nozzle should be used, min. 45° spread
• Distance from nozzle to encapsulation: min. 0.4
m
• Flow: max. 20 liters/min (1).
Steam cleaner • Water pressure at nozzle: max. 2,500 kN/m 2 (25
bar)
• Type of nozzle: fan jet, min. 45° spread
• Distance from nozzle to encapsulation: min. 0.4
m
• Water temperature: max. 80° C

1) Typical tap water pressure and flow

Cables
Movable cables need to be able to move freely:
• Remove waste material, for example sand, dust, and chips, if it prevents cable
movement.
• Clean the cables if they have a crusty surface for example from dry release agents.

Do's and don'ts!

The section below specifies some special considerations when cleaning the robot.
Always!
• Always use cleaning equipment as specified above! Any other cleaning equipment
© Copyright 2004-2010 ABB. All rights reserved.

may shorten the life of the robot.

• Always check that all protective covers are fitted to the robot before cleaning!
Never!
• Never point the water jet at connectors, joints, sealings or gaskets!
• Never use compressed air to clean the robot!
• Never use solvents that are not approved by ABB to clean the robot!
• Never spray from a distance closer then 0.4m!
• Never remove any covers or other protective devices before cleaning the robot!

3HAC022032-001 Revision: H 105

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.

Oil in gears, IRB 4400/45, /60, /L30, /L10 and IRB 4450S

Gear... Art. no. Volume Note

Axis 1 1171 2016-604 8,200 ml
Axis 2-3 1171 2016-604 5,800 ml

The lubricating oil specified above corresponds to:

• Mobilgear 600 XP320
• Mobilgear 632

Oil in gears, IRB 4400/FS

Gear... Art. no. Volume Note

Axis 1 1171 2016-604 10,000 ml
Axis 2-3 1171 2016-604 6,000 ml

The lubricating oil specified above corresponds to:

• Mobilgear 600 XP320
• Mobilgear 632

© Copyright 2004-2010 ABB. All rights reserved.

106 3HAC022032-001 Revision: H

 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.
Note! The location of these oil plugs on the IRB 4450S is slightly different compared to the
other robot versions.

xx0300000331

A Oil plug, filling

Location of oil plugs, axis 4

The axis 4 gearbox has one oil plug for draining and one oil plug for filling, located as shown
in the figure below.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000220

A Upper oil plug, filling

B Lower oil plug, draining

Continues on next page

3HAC022032-001 Revision: H 107
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.

xx0300000223

A Oil plug, draining (2 pcs, the other oil plug not shown in figure)
B Oil plug, filling (also used for draining)

Location of oil plugs, axes 5 and 6 (only IRB 4400/L10)

The wrist unit has one oil plug for draining the oil and one oil plug for filling, located as
shown in the figure below. The oil plug for filling is also used as an air inlet when draining
the oil.

© Copyright 2004-2010 ABB. All rights reserved.

xx0300000118

A Oil plug, draining

B Oil plug, filling (also used as air inlet when draining)

Continues on next page

108 3HAC022032-001 Revision: H
 3 Maintenance
3.4.2. Inspection of oil levels

Continued

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
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.

Inspection, oil level axis 2-3

The procedure below details how to inspect the oil level of the gearbox unit, axes 2-3.

Step Action Note/Illustration

1. Remove the oil plug, filling. Shown in the figure Location
of oil plugs, axes 2 and 3 on
page 107.
2. Measure the oil level from the oil plug hole. The oil must cover at least
Required oil level: 225 mm ± 25 mm. half of the lower arm
bearing!
3. Fill or drain, if necessary. Type of oil is detailed in
section Oil in gearbox unit,
axis 1-2-3 on page 106.
4. Clean and refit the oil plug.

Inspection, oil level axis 4

The procedure below details how to inspect the oil level of the gearbox, axis 4.
WARNING!
© Copyright 2004-2010 ABB. All rights reserved.

Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!
WARNING!
When filling gearbox oil, do not mix different types of oil 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!

Step Action Info/Illustration

1. Move the upper arm to a horizontal position (calibra-
tion position).
2. Remove the upper oil plug, filling. Shown in the figure Location
of oil plugs, axis 4 on page
107.

Continues on next page

3HAC022032-001 Revision: H 109
3 Maintenance
3.4.2. Inspection of oil levels

Continued

Step 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 111.
5. Refit the oil plug.

Inspection, oil level axis 5 and 6 (all robot versions except IRB 4400/L10)
The procedure below details how to inspect the oil level of wrist unit, axis 5 and 6 for all robot
versions except IRB 4400/L10.

Step Action Note/Illustration

1. Move the robot to the calibration position.
2. Remove one of the oil plugs, draining at the rear of Shown in the figure Location
the wrist. of oil plugs, axes 5 and 6 (all
robot versions except IRB
4400/L10) on page 108.
3. Required oil level: on level with 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 5 and 6 (all robot
versions except IRB 4400/
L10) on page 114.
5. Refit the oil plug.

Inspection, oil level axis 5 and 6 (IRB 4400/L10)

The procedure below details how to inspect the oil level of wrist unit, axis 5 and 6 for robot
version IRB 4400/L10.

Step Action Note/Illustration

1. Move the robot to a position where the upper arm is © Copyright 2004-2010 ABB. All rights reserved.
close to horizontal and axis 4 in the calibration
position.
2. Remove the oil plug, filling from the side of the wrist. Shown in the figure Location
of oil plugs, axes 5 and 6
(only IRB 4400/L10) on page
108
3. Required oil level: on level with 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 5 and 6 (IRB 4400/L10
only) on page 117.
5. Refit the oil plug.

110 3HAC022032-001 Revision: H

 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

A Upper oil plug, filling

B Lower oil plug, draining

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Lubricating oil 3HAC 0860-1 Optimol Optigear BM 100
Volume: 3,400 ml.
Standard toolkit 3HAC 17594-1 The content is defined in
the section Standard toolkit
© Copyright 2004-2010 ABB. All rights reserved.

on page 275.
Oil collecting vessel Capacity: 4,000 ml.
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.

Continues on next page

3HAC022032-001 Revision: H 111
3 Maintenance
3.4.3. Oil change, gearbox axis 4

Continued

Draining
The procedure below details how to drain the oil from the gearbox, axis 4.
TIP!
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!

Step Action Info/Illustration

1. Move the arms backward and the upper arm to a
nearly vertical position.
2. Remove the lower oil plug, draining and drain the oil Shown in the figure Location
into an oil collecting vessel. of oil plugs on page 111.
Capacity of the oil collecting
vessel is specified in
Required equipment on
page 111.
3. Clean and refit the oil plug.

Filling
The procedure below details how to refill the oil to the gearbox, axis 4.
NOTE!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may differ from the specified amount, depending on how much
oil has previously been drained from the gearbox.
WARNING!

© Copyright 2004-2010 ABB. All rights reserved.

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!
WARNING!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure
inside the gearbox which in turn may:
• - damage seals and gaskets
• - completely press out seals and gaskets
• - prevent the manipulator from moving freely

Continues on next page

112 3HAC022032-001 Revision: H
 3 Maintenance
3.4.3. Oil change, gearbox axis 4

Continued

Step Action Note/Illustration

1. Move the upper arm to a vertical position (rear end
upwards).
2. Remove the upper oil plug, filling. Shown in the figure Location
of oil plugs on page 111.
3. Fill the gearbox with lubricating oil. Amount and art. no. is
specified in Required
equipment on page 111.
Correct oil level is specified
in section Inspection of oil
levels on page 107.
4. Clean and refit the oil plug.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 113

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.

xx0300000223

A Oil plug, draining (2 pcs, the other oil plug not shown in figure)
B Oil plug, filling (also used for draining)

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Lubricating oil 3HAC 0860-1 Optimol Optigear BM 100
Volume: 3,400 ml
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
Oil collecting vessel Capacity: 4,000 ml
Other tools and These procedures include
© Copyright 2004-2010 ABB. All rights reserved.
procedures may be references to the tools
required. See references required.
to these procedures in the
step-by-step instructions
below.

Continues on next page

114 3HAC022032-001 Revision: H
 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).
TIP!
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!

Step Action Info/Illustration

1. Move the upper arm to a horizontal position and turn
axis 4 to the calibration position.
2. Turn axis 4 135°.
3. Remove the lower oil plug, draining at the rear of the Shown in the figure Location
wrist. of oil plugs on page 114.
Capacity of oil collecting
vessel is specified in
Required equipment on
page 114.
4. Remove the other oil plug, draining.
5. Move axis 3 up -15° and let the oil run out for a couple
of minutes.
6. Turn axis 4 so that the oil plug, filling is facing Shown in the figure Location
downwards. of oil plugs on page 114.
7. Remove the oil plug, axis 5 to drain the oil.
8. Move axis 3 down to 0°.
9. Move axis 4 backwards and forwards a couple of
times to drain all the oil.
© Copyright 2004-2010 ABB. All rights reserved.

10. Clean and refit the both oil plugs, draining.

Continues on next page

3HAC022032-001 Revision: H 115
3 Maintenance
3.4.4. Oil change, gearbox axis 5 and 6 (all robot versions except IRB 4400/L10)

Continued

Filling oil
The procedure below details how to fill oil to the wrist unit (axis 5 and 6).
NOTE!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may differ from the specified amount, depending on how much
oil has previously been drained from the gearbox.
WARNING!
When filling gearbox oil, do not mix different types of oil 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!
WARNING!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure
inside the gearbox which in turn may:
• - damage seals and gaskets
• - completely press out seals and gaskets
• - prevent the manipulator from moving freely

Step Action Note/Illustration

1. Move the upper arm to a horizontal position and turn
axis 4 to calibration position.
2. Turn axis 4 so that the oil plug, filling is facing Shown in the figure Location
upwards. of oil plugs on page 114.
3. Fill the wrist with lubricating oil through the oil plug Art. no. and amount is
hole, filling. specified in Required
Fill in intervals so that the oil runs into the wrist. equipment on page 114.
Correct oil level is specified
in section Inspection of oil
levels on page 107.

© Copyright 2004-2010 ABB. All rights reserved.

4. Clean and refit the oil plug, filling.

116 3HAC022032-001 Revision: H

 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. The oil plug for filling is also used as an air inlet when draining
the oil.

xx0300000118

A Oil plug, draining

B Oil plug, filling (also used as air inlet when draining)

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Lubricating oil 3HAC 0860-1 Optimol Optigear BM 100
Volume: 800 ml
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on page
275.
© Copyright 2004-2010 ABB. All rights reserved.

Oil collecting vessel Capacity: 1000 ml

Other tools and These procedures include
procedures may be references to the tools required.
required. See references
to these procedures in the
step-by-step instructions
below.

Continues on next page

3HAC022032-001 Revision: H 117
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.
TIP!
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
WARNING!
Changing and draining gearbox oil may require handling hot oil of up to 90 °C! Make sure
that protective gear like goggles and gloves are always worn during this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil plug, there
may be pressure present in the gearbox, causing oil to spray from the opening!

Step Action Info/Illustration

1. Move the upper arm to a horizontal position and turn
axis 4 to the calibration position.
2. Remove the oil plug, draining in the wrist. Shown in the figure Location
of oil plugs on page 117.
3. Turn axis 4 to a position where the oil plug, draining Shown in the figure Location
is faced downwards and drain the oil into an oil of oil plugs on page 117.
collecting vessel. Capacity of vessel is
Also remove the oil plug, filling, in order to use it as an specified in Required
air inlet. equipment on page 117.
4. Turn axis 4 another 90° to allow the remaining oil to
be drained.
5. Clean and refit the oil plug, draining.

© Copyright 2004-2010 ABB. All rights reserved.

Continues on next page

118 3HAC022032-001 Revision: H
 3 Maintenance
3.4.5. Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only)

Continued

Filling oil
The procedure below details how to fill oil to the wrist unit (axis 5 and 6), robot version IRB
4400/L10.
NOTE!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may differ from the specified amount, depending on how much
oil has previously been drained from the gearbox.
WARNING!
When filling gearbox oil, do not mix different types of oil 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!
WARNING!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
• - damage seals and gaskets
• - completely press out seals and gaskets
• - prevent the manipulator from moving freely

Step Action Note/Illustration

1. Move the upper arm to a horizontal position and turn
axis 4 to the calibration position.
2. Fill the wrist with lubricating oil through the oil plug Art. no. and amount are
hole, filling. specified in Required
equipment on page 117.
Correct oil level is specified
in section Inspection of oil
levels on page 107.
3. Clean and refit the oil plug, filling.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 119

3 Maintenance
3.4.5. Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only)

© Copyright 2004-2010 ABB. All rights reserved.

120 3HAC022032-001 Revision: H

 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 the information required to perform the activity, for example spare parts numbers,
required special tools and materials.
The procedures are gathered in sections, divided according to the component location on the
robot.

Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in chapter Reference information.

Safety information
Before any service work is commenced, it is extremely important that all safety information
is read!
There are general safety aspects that must be read through, as well as more specific safety
information that describes the danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety on page 13 before commencing any
service work.
NOTE!
If the robot is connected to power, always make sure that the robot is connected to earth
before starting any repair work!
For more information see:
© Copyright 2004-2010 ABB. All rights reserved.

• Product manual - IRC5

• Product manual - Panel Mounted Controller.

3HAC022032-001 Revision: H 121

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 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. Art. no. Note

Leakdown tester 3HAC0207-1
Leak detection spray -

Procedure

Action Note
1. Finish the refitting procedure of the motor or gear in
question.
2. Remove the topmost oil plug on the gear in question Art. no. is specified in Required
and replace it with the leakdown tester. equipment on page 122.
Adapters, which are included in the leakdown tester
kit, may be required.
3. Apply compressed air and raise the pressure with the Recommended value:
knob until the correct value is shown on the 0.2 - 0.25 bar (20 - 25 kPa)
manometer.
4. Disconnect the compressed air supply.
5. Wait for approx. 8-10 minutes. No pressure loss may If the compressed air is signifi-
be detected. cantly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.

© Copyright 2004-2010 ABB. All rights reserved.

6. Was any pressure drop evident?
Localize the leak as detailed below.
Remove the leakdown tester and refit the oil plug.
The test is complete.
7. Spray suspected leak areas with leak detection spray.
Bubbles indicate a leak.
8. When the leak has been localized, take the necessary
measures to correct the leak.

122 3HAC022032-001 Revision: H

 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 3HAB3537-1 Used to grease the bearings, if not
specified otherwise.

Assembly of all bearings

Follow the instructions below when mounting a bearing on the robot.

Action Note
1. To avoid contamination, let a new bearing remain in its wrapping
until it is time for fitting.
2. Ensure that all parts included in the bearing fitting are free from
burrs, grinding waste and other contamination. Cast components
must be free from foundry sand.
3. Bearing rings, inner rings and roller elements must under no cir-
cumstances be subjected to direct impact. Furthermore, the roller
elements must not be exposed to any stresses during the assembly
work.

Assembly of tapered bearings

Follow the previous instructions for assembly of all bearings when mounting a tapered
bearing on the robot.
In addition to those instructions, the procedure below must be carried out to enable the roller
elements to adjust to the correct position against the race flange.
© Copyright 2004-2010 ABB. All rights reserved.

Action Note
1. Tension the bearing gradually until the recommended pre-tension
is achieved.

NOTE!
The roller elements must be rotated a specified number of turns
before pre-tensioning is carried out and also rotated during the pre-
tensioning sequence.
2. Make sure the bearing is properly aligned as this will directly affect
the lifespan of the bearing.

Continues on next page

3HAC022032-001 Revision: H 123
4 Repair
4.2.2. Mounting instructions for bearings

Continued

Greasing of bearings
The bearings must be greased after assembly in accordance to the instructions below:
• The bearings must not be completely filled with grease. However, if space is available
beside the bearing fitting, the bearing may be totally filled with grease when mounted,
as excessive grease will be pressed out from the bearing when the robot is started.
• During operation, the bearing should be filled to 70-80% of the available volume.
• Ensure that grease is handled and stored properly to avoid contamination.
Grease the different types of bearings as detailed below:
• Grooved ball bearings must be filled with grease from both sides.
• Tapered roller bearings and axial needle bearings must be greased in the split
condition.

© Copyright 2004-2010 ABB. All rights reserved.

124 3HAC022032-001 Revision: H

 4 Repair
4.2.3. Mounting instructions for seals

4.2.3. Mounting instructions for seals

General
This section details how to mount different types of seals onto the robot.

Equipment

Equipment, etc. Art. no. Note

Grease 3HAB3537-1 Used to lubricate the seals.

Rotating seals
The procedure below details how to fit rotating seals.
CAUTION!
Please observe the following before commencing any assembly of seals:
• Protect the sealing surfaces during transport and mounting.
• Keep the seal in its original wrappings or protect it well before actual mounting.
• The fitting of seals and gears must be carried out on clean workbenches.
• Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
keyways, etc.

Action Note
1. Check the seal to ensure that:
• the seal is of the correct type (provided with cutting
edge).
• there is no damage to the sealing edge (feel with a
fingernail).
2. Inspect the sealing surface before mounting. If scratches or
damage are found, the seal must be replaced since it may
result in future leakage.
3. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in
© Copyright 2004-2010 ABB. All rights reserved.

early - there is a risk of dirt and foreign particles adhering to Equipment on page 125.
the seal.)
Fill 2/3 of the space between the dust tongue and sealing lip
with grease. The rubber coated external diameter must also
be greased, unless otherwise specified.
4. Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.

Continues on next page

3HAC022032-001 Revision: H 125
4 Repair
4.2.3. Mounting instructions for seals

Continued

Flange seals and static seals

The procedure below details how to fit flange seals and static seals.

Action
1. Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing
compound).
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.
4. Tighten the screws evenly when fastening the flange joint.

O-rings
The procedure below details how to fit o-rings.

Action Note
1. Ensure that the correct o-ring size is used.
2. Check the o-ring for surface defects, burrs, Defective o-rings may not be used.
shape accuracy, etc.
3. Check the o-ring grooves. Defective o-rings may not be used.
The grooves must be geometrically correct and
free from pores and contamination.
4. Lubricate the o-ring with grease.
5. Tighten the screws evenly when assembling.

© Copyright 2004-2010 ABB. All rights reserved.

126 3HAC022032-001 Revision: H

 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. Also see the following figure for the view X-X.
Note! The figures show the robot model IRB 4400. But the basic principle of the location of
the cable harness axes 1-3 for the IRB 4450S is similair. Cables are longer though.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000111

A Rear cover plate

B Connectors at the base. Connectors at the rear cover plate: R1.MP,
R1.SMB, R1.CP/CS, R2.MP4-6. Brake release connectors: R2.BU,
R2.BU1-3, R2.BU4-6. Connectors at serial measurement unit: R2.SMB,
R2.FB1-3, R2.FB4-6.

Continues on next page

3HAC022032-001 Revision: H 127
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

C Connection box, motor 1. Connectors at motor 1: R3.MP1, R3.FB1.

D Connection box, motor 2. Connectors at motor 2: R3.MP2, R3.FB2.
E Connection box, motor 3. Connectors at motor 3: R3.MP3, R3.FB3.
G Cable guides in the middle of axis 1
H Protection plate

Required equipment
© Copyright 2004-2010 ABB. All rights reserved.
Equipment, etc. Spare part no. Art. no. Note
Cable harness, axes 1-3 3HAC5958-1 IRB 4400 all models,
(except IRB 4450S)
Cable harness, axes 1-3 3HAC 025479-001 IRB 4450S
Gasket 3HAC 4432-1 Between the motor and
the connection box, axes
1, 2 and 3.
Replace if damaged.
Standard toolkit 3HAC 17594-1 The content is defined in
the section Standard
toolkit on page 275.
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 instruc-
tions below.

Continues on next page

128 3HAC022032-001 Revision: H
 4 Repair
4.3.1. Replacement of cable harness, axes 1-3

Continued

Equipment, etc. Spare part no. Art. no. Note

Circuit diagram See the chapter Circuit
diagram.
Calibration Pendulum General calibration
Instruction information is included in
the section Calibration
information on page 247.

Removal, cabling axes 1-3

The procedure below details how to remove the cable harness from the axes 1-3.

Step Action Info/Illustration

1.

DANGER!
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.
2. Remove the rear cover plate. Shown in the figure Location
of cable harness, axes 1-3
on page 127.
3. Remove the serial measurement unit. Removal detailed in section
Removal, serial
measurement unit on page
192.
4. Loosen the connectors R1.MP1, R2.FB1-3, R2.BU, Shown in the figure Location
R2.BU1-3. Also loosen the earth connections. of cable harness, axes 1-3
on page 127.
5. Cut all the ties around bundle.
6. Remove the cable bracket inside the base.
7. Remove the cable guides and the protection plate in Shown in the figure Location
© Copyright 2004-2010 ABB. All rights reserved.

the middle of axis 1. of cable harness, view X-X

on page 128.
8. Remove the covers from the connections boxes for
the motors in axes 1-2-3.
9. Loosen all the connectors to the motors of axes 1-2-3. Shown in the figure Location
of cable harness, view X-X
on page 128.
10. Remove the connection boxes from the motors 1-2-3.
11. Feed the cabling up through the middle of axis 1 and
remove the complete cabling.
Tip! Gather the loose cabling and connectors into a
package with tape in order to protect the connectors
and make the cabling easier to handle.

Continues on next page

3HAC022032-001 Revision: H 129
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.

Step Action Info/Illustration

1.

DANGER!
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.
2. Feed the cable harness, axes 1-3 through the Part no. is specified in
protection plate and down through the middle of axis Required equipment on
1. page 128
Tip! Gather the loose cabling and connectors into a
package with tape in order to protect the connectors
and make the cabling easier to handle.
3. Refit the connection boxes to the motors 1-2-3. Part no. is specified in
Replace the gaskets if they are damaged. Required equipment on
page 128
4. Reconnect the connectors in the motors 1-2-3. Shown in the figure Location
of cable harness, view X-X
on page 128
5. Refit the cable guide and the protection plate in the Shown in the figure Location
middle of axis 1. of cable harness, view X-X
on page 128
6. Secure the cabling with straps, according to foldout 3. See the Foldouts in the
Product manual, reference
information.
7. Refit the cable bracket inside the base.
8. Reposition the cabling inside the base according to See the Foldouts in the
foldout 4. Product manual, reference
information.
9. Reconnect all connectors at the base. © Copyright 2004-2010 ABB. All rights reserved.
10. Refit the serial measurement unit. Detailed in Refitting, serial
measurement unit on page
193
11. Refit the rear cover plate. Shown in the figure Location
of cable harness, axes 1-3
on page 127
12. Refit the covers of the connection boxes.
13. Recalibrate the robot! Calibration is detailed in a
separate calibration manual
enclosed with the calibration
tools.
General calibration
information is included in the
section Calibration
information on page 247.

Continues on next page

130 3HAC022032-001 Revision: H
 4 Repair
4.3.1. Replacement of cable harness, axes 1-3

Continued

Step Action Info/Illustration

14.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may
cause injury or damage! on page 39.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 131

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.
Also see the following figure for the view X-X.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

© Copyright 2004-2010 ABB. All rights reserved.

xx0300000111

A Rear cover plate

B Connectors at the base. Connectors at the rear cover plate: R1.MP,
R1.SMB, R1.CP/CS (customer connection), R2.MP4-6. Brake release
connectors: R2.BU, R2.BU1-3, R2.BU4-6. Connectors at serial
measurement unit: R2.SMB, R2.FB1-3, R2.FB4-6.
F Connection box, motor 4, 5 and 6. Connectors to the motors at upper arm:
R3.MP4, R3.MP5, R3.MP6, R3.FB4, R3.FB5, R3.FB6. Customer connec-
tions: R2.CP, R2.CS.
I Cable bracket inside the lower arm
J Cable bracket at the upper arm

Continues on next page

132 3HAC022032-001 Revision: H
 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

C Connection box, motor 1. Connectors at motor 1: R3.MP1, R3.FB1.

D Connection box, motor 2. Connectors at motor 2: R3.MP2, R3.FB2.
E Connection box, motor 3. Connectors at motor 3: R3.MP3, R3.FB3.
G Cable guides in the middle of axis 1
H Protection plate

Required equipment
© Copyright 2004-2010 ABB. All rights reserved.

Equipment, etc. Spare part no. Art. no. Note

Cable harness, axes 4-6 3HAC 8304-1 IRB 4400 all models
(except IRB 4450S)
Cable harness, axes 4-6 3HAC 025480-001 IRB 4450S
Gasket 3HAB 3676-1 3 pcs
Between the motor and
the connection box.
Replace if damaged.
Standard toolkit 3HAC 17594-1 The content is defined in
the section Standard
toolkit on page 275.
Other tools and These procedures
procedures may be include references to the
required. See references tools required.
to these procedures in the
step-by-step instructions
below.

Continues on next page

3HAC022032-001 Revision: H 133
4 Repair
4.3.2. Replacement of cable harness, axes 4-6

Continued

Equipment, etc. Spare part no. Art. no. Note

Circuit Diagram See the chapter Circuit
diagram.
Calibration Pendulum Calibration is detailed in a
Instruction separate calibration
manual enclosed with the
calibration tools.
Art. no. is specified in
section Document
references on page 273in
part 2 of the Product
manual.

Removal, cabling axes 4-6

The procedure below details how to remove the cable harness from the axes 4-6.

Step Action Info/Illustration

1.

DANGER!
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.
2. Remove the cover ot the connection box for
motors 4-5-6.
3. Remove the rear cover plate. Shown in the figure Location of cable
harness, axes 4-6 on page 132
4. Remove the serial measurement unit. Detailed in section Removal, serial
measurement unit on page 192
5. Loosen the connectors R2.MP4-6, R2.FB4- Shown in the figure Location of cable
6, R2.BU4-6, R1.CP/CS. Also loosen the harness, axes 4-6 on page 132
earth connections.
6. Cut all the straps around the bundle. © Copyright 2004-2010 ABB. All rights reserved.

7. Remove the cable bracket inside the base.

8. Remove the cable guides and the protection Shown in the figureLocation of cable
plate in the midle of axis 1. harness, view X-X on page 133

Continues on next page

134 3HAC022032-001 Revision: H
 4 Repair
4.3.2. Replacement of cable harness, axes 4-6

Continued

Step 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.
Tip! Gather the loose cabling and
connectors into a package with tape in order
to protect the connectors and make the
cabling easier to handle.
11. Loosen the cable bracket inside the lower Shown in the figure Location of cable
arm and undo the two screws. harness, axes 4-6 on page 132
12. Loosen the cable bracket at the upper arm. Shown in the figure Location of cable
harness, axes 4-6 on page 132
13. Loosen all the connectors to the motors at Shown in the figure Location of cable
the upper arm and customer connections, if harness, axes 4-6 on page 132
any.
14. Remove the connection box together with
the cabling.
© Copyright 2004-2010 ABB. All rights reserved.

Continues on next page

3HAC022032-001 Revision: H 135
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

A Axis 4 motor
A1 Connector R3.MP4
A2 Connector R3.FB4
B Axis 5 motor
B1 Connector R3.MP5
B2 Connector R3.FB5
C Axis 6 motor
C1 Connector R3.MP6
C2 Connector R3.FB6
D Protection plate © Copyright 2004-2010 ABB. All rights reserved.
E Cable strap, indoor
F cable strap, outdoor

Continues on next page

136 3HAC022032-001 Revision: H
 4 Repair
4.3.2. Replacement of cable harness, axes 4-6

Continued

Refitting, cabling axes 4-6

The procedure below details how to refit the cable harness to the axes 4-6.

Step Action Info/Illustration

1.

DANGER!
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.
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 133.
Replace them if damaged.
3. Refit the connection box.
Make sure the gaskets are seated properly!
4. Reconnect all the connectors and reposition the Connectors and correct
cabling inside the connection box using straps. positioning are shown in the figure
Connection box, upper arm on
page 136.
5. Refit the protection plate in the connection box. Shown in the figure Connection
box, upper arm on page 136.
6. Run the cabling through the lower arm.
7. Refit the cable bracket at the upper arm. Shown in the figure Location of
cable harness, axes 4-6 on page
132.
8. Refit the cable bracket inside the lower arm. Shown in the figure Location of
cable harness, axes 4-6 on page
132.
9. Feed the cabling through the protection plate Shown in the figure Location of
and down through the axis 1. cable harness, view X-X on page
133.
© Copyright 2004-2010 ABB. All rights reserved.

10. Refit the cable brackets (A) between the

gearboxes of axes 2 and 3 and strap the
cabling.

xx0300000113

11. Refit the cable bracket inside the base.

12. Put straps around the bundle and position the See the Foldouts on page 289 in
cabling at the base according to foldout 4. the Product manual, reference
information.
13. Reconnect all the connectors at the base.
Continues on next page
3HAC022032-001 Revision: H 137
4 Repair
4.3.2. Replacement of cable harness, axes 4-6

Continued

Step Action Info/Illustration

14. Refit the serial measurement unit. Detailed in Refitting, serial
measurement unit on page 193.
15. Refit the rear cover plate. Shown in the figure Location of
cable harness, axes 4-6 on page
132.
16. Refit the cover of the connection box in the
upper arm.
17. Recalibrate the robot! Calibration is detailed in a
separate calibration manual
enclosed with the calibration tools.
General calibration information is
included in the section Calibration
information on page 247.
18.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on page
39.

© Copyright 2004-2010 ABB. All rights reserved.

138 3HAC022032-001 Revision: H

 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 in
the Product manual, reference information.

xx0300000143

A Lower arm
B Upper arm
© Copyright 2004-2010 ABB. All rights reserved.

C Attachment screws and friction washers, lower arm

D Parallel arm
E V-ring between lower arm and gearbox axis 3

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
V-ring 3HAB 3773-11 2 pcs.
On both sides of the lower
arm, in the frame.
Grease 3HAB 3537-1 Used to grease sealings and
bearings.
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.

Continues on next page

3HAC022032-001 Revision: H 139
4 Repair
4.3.3. Replacement of complete arm system

Continued

Spare part
Equipment, etc. Art. no. Note
no.
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.
Calibration Pendulum General calibration
Instruction information is included in the
section Calibration
information on page 247.

Removal, complete arm system

The procedure below details how to remove the complete arm system from the robot.
Note! The following procedure also applies to the IRB 4450S.

Step Action Info/Illustration

1.

DANGER!
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.
2.

CAUTION!
The complete arm system weighs 232 kg! All lifting
equipment used must be sized accordingly!
3. Remove the tie rod. Detailed in section

© Copyright 2004-2010 ABB. All rights reserved.

Replacement of tie rod on page
175.
4. Remove the cabling down to axis 1. Detailed in section Removal of
cable harness, axes 4-6.

Continues on next page

140 3HAC022032-001 Revision: H
 4 Repair
4.3.3. Replacement of complete arm system

Continued

Step 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.
Note! If the arms are not properly secured, the
upper arm may move during the lift and cause a
drop of the complete arm system.

xx0300000142

Note! The figure shows the IRB

4400.
The same position of the upper
arm resting against the lower
arm, should be applied for the
IRB 4450S.
6. Unload the weight of the arm system with lifting
slings and a crane.
7. Remove the balancing device. Detailed in section
Replacement of balancing
device on page 183.
8. Remove the parallel arm. Detailed in section
© Copyright 2004-2010 ABB. All rights reserved.

Replacement of parallel arm /

Replacement of bearing on
page 179.
9. Remove the attachment screws and friction Shown in the figure Location of
washers, lower arm. complete arm system on page
139.
10. Lift away the complete arm system.
Make sure the upper and lower arm are properly
secured to each other during the lift.

Continues on next page

3HAC022032-001 Revision: H 141
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.

Step Action Info/Illustration

1.

DANGER!
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.
2.

CAUTION!
The complete arm system weighs 232 kg! All
lifting equipment used must be sized accord-
ingly!
3. Check and grease both of the V-rings in the Part no. is specified in Required
frame. Replace if damaged. equipment on page 139
4. Lift the arm system into mounting position.
Make sure the arms are properly secured to
each other (A), as shown in the figure to the
right.

© Copyright 2004-2010 ABB. All rights reserved.

xx0300000142

Note! The figure shows the IRB

4400.
The same position of the upper
arm resting against the lower arm,
should be applied for the IRB
4450S.

Continues on next page

142 3HAC022032-001 Revision: H
 4 Repair
4.3.3. Replacement of complete arm system

Continued

Step 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 139
6. Grease the bearing seating of the parallel arm
in the lower arm, to prevent clicking during
operation.
7. Refit the parallel arm. Detailed in section Refitting,
parallel arm/bearing on page 181
8. Refit the balancing device. Detailed in section Refitting of
balancing device on page 188
9. Move the upper arm to a horizontal position.
10. Refit the tie rod. Detailed in section Refitting, tie rod
on page 177
11. Refit the cabling to the upper arm. Detailed in section Refitting,
cabling axes 4-6 on page 137
12. Recalibrate the robot! Calibration is detailed in a separate
calibration manual enclosed with
the calibration tools.
General calibration information is
included in the section Calibration
information on page 247.
13.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on page
39.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 143

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 in
the Product manual, reference information.

xx0300000129

© Copyright 2004-2010 ABB. All rights reserved.

A Upper arm
B Connectors of motors, axes 4, 5 and 6
C Connection box, upper arm
D Calibration plate, axis 3
E VK cover
F KM nut
G Screw
H Bearing
I Sealing ring
J Shaft end

Continues on next page

144 3HAC022032-001 Revision: H
 4 Repair
4.4.1. Replacement of complete upper arm

Continued

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
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 3HAC 4744-1
Grease 3HAB 3537-1 Used to grease the bearing.
Locking liquid Loctite 243
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
Dismounting tool 3HAC 0163-1 Used to pull out the shaft.
Mounting tool 3HAB 1463-1 Used to fit the inner ring of the
bearing.
Contains two separate parts.
De-air tool 3HAC 8704-1 Used to evacuate air when
refitting VK-cover, if the cover
has no grooves for venting.
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.
Calibration Pendulum Art. no. is specified in section
Instruction Document references on
page 273in part 2 of the
Product manual.
© Copyright 2004-2010 ABB. All rights reserved.

Continues on next page

3HAC022032-001 Revision: H 145
4 Repair
4.4.1. Replacement of complete upper arm

Continued

Removal, upper arm

The procedure below how to remove the complete upper arm from the robot.
Note! The following procedure also applies to the IRB 4450S.

Step Action Info/Illustration

1.

DANGER!
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.
2.

CAUTION!
The complete arm system weighs 232 kg! All lifting
equipment used must be sized accordingly!
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 176
6. Loosen the connectors of motors, axes 4, 5 and 6. Shown in the figure Location
of upper arm on page 144
7. Remove the connection box, upper arm from the Shown in the figure Location
motors. of upper arm on page 144
8. Remove the calibration plate, axis 3. Shown in the figure Location
of upper arm on page 144
9. Remove the VK covers on both sides of the upper Shown in the figure Location
arm. of upper arm on page 144
Be careful with the bearing beneath the cover! Make
© Copyright 2004-2010 ABB. All rights reserved.
a hole in the outer edge of the cover and bend it away.
10. Undo the KM nuts. Shown in the figure Location
of upper arm on page 144
11. Remove the screws. Shown in the figure Location
of upper arm on page 144
12. Pull out the shaft with the dismounting tool. Art.no. is specified in
Mark the shafts (left and right)! Required equipment on
page 145
13. Remove the sealings and bearings, if damaged. Shown in the figure Location
of upper arm on page 144
14. Remove the upper arm from the manipulator.

Continues on next page

146 3HAC022032-001 Revision: H
 4 Repair
4.4.1. Replacement of complete upper arm

Continued

Refitting, upper arm

The procedure below details how to refit the complete upper arm to the robot.
Note! The following procedure also applies to the IRB 4450S.

Step Action Info/Illustration

1.

DANGER!
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.
2.

CAUTION!
The complete arm system weighs 232 kg! All
lifting equipment used must be sized accordingly!
3. Fit the sealings and the outer ring of the bearings Shown in the figure Location of
in the upper arm, if removed. upper arm on page 144.
The bearing must be completely filled with Part no. is specified in Required
grease. equipment on page 145.
4. Lower the upper arm into mounting position.
5. Refit both shaft ends. Shown in the figure Location of
upper arm on page 144.
Part no. is specified in Required
equipment on page 145.
6. Insert both screws. Shown in the figure Location of
upper arm on page 144.
2 pcs, tightening torque: 470
Nm.
7. If the bearing is removed, the inner ring of the Art. no. is specified in Required
© Copyright 2004-2010 ABB. All rights reserved.

bearing is fitted as follows: equipment on page 145.

• Fit the holding-on tool (part A of the
mounting tool) on the right side of the
upper arm (seen from behind).
• Fit the inner ring (C) of the bearing on the
left side of the upper arm, using the press
tool (part B of the mounting tool).
• Remove the holding-on tool and fit the
inner ring also on that side. xx0300000130

• A: Holding-on tool
• B: Press tool
• C: Inner ring
8. Apply locking liquid on the threads of the KM nut. Locking liquid specified in
Required equipment on page
145
Shown in the figure Required
equipment on page 145.

Continues on next page

3HAC022032-001 Revision: H 147
4 Repair
4.4.1. Replacement of complete upper arm

Continued

Step Action Info/Illustration

9. Tighten the KM nut...
• on the left side, with torque 95 Nm in
order to center the upper arm
• on the right side first with 105 Nm. Then
unscrew the KM nut and re-tighten it with
torque 95 Nm.
Note! This procedure must be performed within
10 minutes, before the Loctite begins to harden.
10. Fit new VK covers. Part no. is specified in Required
Note! If the covers have no grooves for venting, equipment on page 145.
the air must be evacuated by using the de-air tool Shown in the figure Location of
(A). Also use a clamp as an aid in positioning the upper arm on page 144.
covers tilted, to avoid overpressure.

xx0300000134

• A: De-air tool, used if the

VK-cover has no grooves
for venting.
11. Refit the tie rod. Detailed in section Refitting of tie
rod.
12. Refit the calibration plate, axis 3. Shown in the figure Location of
upper arm on page 144.
13. Refit the connection box. Shown in the figure Location of
upper arm on page 144.
14. Reconnect the connectors to motors, axes 4, 5 Shown in the figure Location of
and 6. upper arm on page 144.
15. Recalibrate the robot! Calibration is detailed in a
separate calibration manual
© Copyright 2004-2010 ABB. All rights reserved.
enclosed with the calibration
tools.
General calibration information
is included in the section
Calibration information on page
247.
16.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 39.

148 3HAC022032-001 Revision: H

 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 in
the Product manual, reference information.

xx0300000150

A Wrist unit
© Copyright 2004-2010 ABB. All rights reserved.

B O-ring
C Sealing surface between wrist unit and upper arm tube
D Attachment screws and washers

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Wrist unit 3HAB 8271-1
(IRB 4400/45, /60, /L30, /S
and IRB 4450S)
Wrist unit 3HAB 9398-1
(IRB 4400/L10)
O-ring 2152 2012-541
(IRB 4400/45, /60, /L30, /S
and IRB 4450S)

Continues on next page

3HAC022032-001 Revision: H 149
4 Repair
4.4.2. Replacement of wrist unit

Continued

Spare part
Equipment, etc. Art. no. Note
no.
O-ring 3HAB 3772-12
(IRB 4400/L10)
Grease 3HAB 3537-1 Used to lubricate the o-ring
groove.
Flange sealing 1234 0011-116 Loctite 574
Standard toolkit 3HAC 17594-1 The content is defined in
the section Standard toolkit
on page 275.
Measuring tool 3HAB 7887-1 Used when mounting the
wrist unit to robot version
IRB 4400/L10.
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.
Calibration Pendulum Art. no. is specified in
Instruction section Document
references on page 273in
part 2 of the Product
manual.

Removal of wrist unit

The procedure below details how to remove the wrist unit from the robot.
NOTE!
This component includes a complete unit comprising motors and gearboxes. It is a
replacement unit of complex design and should not normally be serviced on-site. Instead it
should be sent to ABB for service.
ABB recommends its customers to carry out only the following servicing and repair work on

© Copyright 2004-2010 ABB. All rights reserved.

this unit.

Step Action Info/Illustration

1.

DANGER!
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.
2. Drain the oil from the wrist unit. Draining is detailed in sections Oil
change, gearbox axis 5 and 6 (all
robot versions except IRB 4400/
L10) on page 114

Continues on next page

150 3HAC022032-001 Revision: H
 4 Repair
4.4.2. Replacement of wrist unit

Continued

Step Action Info/Illustration

3. Remove the attachment screws and washers
(A).

xx0300000148

Wrist unit on robot version IRB

4400/45, /60, /L30, /S and IRB
4450S.

xx0300000149

Wrist unit on robot version IRB

4400/L10.
4. Remove the wrist unit from the upper arm.

Refitting, wrist unit IRB 4400/45, /60, /L30, /S and IRB 4450S
The procedure below details how to refit the wrist unit to robot versions IRB 4400/45, /60, /
L30, /S and IRB 4450S.
NOTE!
This component includes a complete unit comprising motors and gearboxes. It is a
replacement unit of complex design and should not normally be serviced on-site. Instead it
should be sent to ABB for service etc.
© Copyright 2004-2010 ABB. All rights reserved.

ABB recommends its customers carry out only the following servicing/repair work on this
unit.

Step Action Info/Illustration

1.

DANGER!
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.
2. Lubricate the o-ring groove in order to Part no. is specified in Required
position the o-ring. equipment on page 149.
Fit the o-ring to the wrist. Shown in the figure Location of wrist
unit on page 149.

Continues on next page

3HAC022032-001 Revision: H 151
4 Repair
4.4.2. Replacement of wrist unit

Continued

Step 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 149.
tube. Sealing surface shown in the figure
Location of wrist unit on page 149.
4. Refit the wrist with attachment screws and
washers (A).

xx0300000148

• A: 8 pcs, M10x35. Tightening

torque: 41 Nm.
5. Fill the wrist unit with oil. Detailed in section Oil change,
gearbox axis 5 and 6 (all robot
versions except IRB 4400/L10) on
page 114.
6. Recalibrate the robot! Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in the section Calibration
information on page 247.
7.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER -

© Copyright 2004-2010 ABB. All rights reserved.

First test run may cause injury or damage!
on page 39.

Continues on next page

152 3HAC022032-001 Revision: H
 4 Repair
4.4.2. Replacement of wrist unit

Continued

Refitting, wrist unit IRB 4400/L10

The procedure below details how to refit the wrist unit to robot version IRB 4400/L10.
NOTE!
This component includes a complete unit comprising motors and gearboxes. It is a
replacement unit of complex design and should not normally be serviced on-site. Instead it
should be sent to ABB for service etc.
ABB recommends its customers carry out only the following servicing/repair work on this
unit.

Step Action Note/Illustration

1.

DANGER!
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.
2. Lubricate and fit the o-ring to the wrist unit. Part no. is specified in Required
equipment on page 149.
Shown in the figure Location of wrist
unit on page 149.
3. Move the upper arm to a vertical position,
wrist side pointing upwards.
4. Refit the wrist unit. Do not tighten the
attachment screws!
5. Release the brakes on axes 5 and 6 (one at Art. no. is specified in Required
a time) and fit the measuring tool at the rear equipment on page 149.
of the motor.
6. Push the wrist to locate the smallest play. Adjustment of play is detailed in
section Refitting of motors axis 5 and
6.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000153

Upper arm seen from front

• A: Gears on drive shaft
• B: Gears on wrist

Continues on next page

3HAC022032-001 Revision: H 153
4 Repair
4.4.2. Replacement of wrist unit

Continued

Step 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. Fill the wrist unit with oil. Detailed in section Oil change,
gearbox axis 5 and 6 (IRB 4400/L10
only) on page 117.
10. Recalibrate the robot! Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in the section Calibration
information on page 247.
11.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER -
First test run may cause injury or damage!
on page 39.

© Copyright 2004-2010 ABB. All rights reserved.

154 3HAC022032-001 Revision: H

 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. (The figure shows the IRB 4400.)
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0300000183

A Upper arm tube

B Axis 4 housing
© Copyright 2004-2010 ABB. All rights reserved.

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Upper arm without wrist 3HAC 17542-1 Foundry, also used for
and motors standard.
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
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.

Continues on next page

3HAC022032-001 Revision: H 155
4 Repair
4.4.3. Replacement of arm house unit, axis 4

Continued

Spare part
Equipment, etc. Art. no. Note
no.
Calibration Pendulum Art. no. is specified in
Instruction section Document
references on page 273in
part 2 of the Product manual.

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!
Caution!
The complete arm house unit weighs 152 kg! All lifting equipment used must be dimensioned
accordingly!

Step Action Info/Illustration

1.

DANGER!
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.
2. Remove the wrist unit. Detailed in section Removal
of wrist unit.
3. Remove the motors for axes 4, 5 and 6. Detailed in section Removal
of motor, axes 4, 5 and 6 on
page 216.
4. Remove the arm house unit. Detailed in section Removal
of complete upper arm.
5. Fit the new arm house unit. Part no. is specified in
Required equipment on © Copyright 2004-2010 ABB. All rights reserved.
page 155.
6. Refit the wrist unit. Detailed in section
Replacement of wrist unit on
page 149.
7. Refit the motors for axes 4, 5 and 6. Detailed in sections
• Refitting of motor,
axis 4 on page 218
• Refitting of motor,
axis 5 on page 221
• Refitting of motor,
axis 6 on page 225

Continues on next page

156 3HAC022032-001 Revision: H
 4 Repair
4.4.3. Replacement of arm house unit, axis 4

Continued

Step 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 the
section Calibration
information on page 247.
9.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may
cause injury or damage! on page 39.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 157

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 in
the Product manual, reference information.

xx0300000176

A Mechanical stop axis 4

B Damper axis 4
C Attachment screws, mechanical stop

© Copyright 2004-2010 ABB. All rights reserved.

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Mechanical stop, axis 4 3HAB 8856-1
Damper 3HAB 3760-1
Flange sealing 1234 0011-116 Loctite 574
Standard toolkit 3HAC 17594-1 The content is defined in
the section Standard
toolkit on page 275.
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.

Continues on next page

158 3HAC022032-001 Revision: H
 4 Repair
4.4.4. Replacement of mechanical stop, axis 4

Continued

WARNING!
If the mechanical stop has been deformed after a hard collision, it must be replaced!

WARNING!
When the damper is removed from axis 4, the axis does not have a mechanical stop! If the
robot is provided with cabling on the upper arm, the cabling can be damaged when the
function Resetting the work area for an axis is used, or if the robot is jogged uncalibrated.

Removal, mechanical stop

The procedure below details how to remove the axis 4 mechanical stop from the robot.

Step Action Info/Illustration

1.

DANGER!
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.
2. Remove the mechanical stop by removing its Shown in the figure Location
attachment screws. of mechanical stop on page
158.
3. Rotate axis 4 so that the damper is visible. Remove Shown in the figure Location
the damper. of mechanical stop on page
158.

Refitting, mechanical stop

The procedure below details how to refit the axis 4 mechanical stop to the robot.

Step Action Note/Illustration

1.
© Copyright 2004-2010 ABB. All rights reserved.

DANGER!
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.
2. Fit the damper to the axis 4. Shown in the figure Location
of mechanical stop on page
158.
Part no. is specified in
Required equipment on
page 158.
3. Apply flange sealing to the stop. Art. no. is specified in
Required equipment on
page 158.

Continues on next page

3HAC022032-001 Revision: H 159
4 Repair
4.4.4. Replacement of mechanical stop, axis 4

Continued

Step 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
158.
Part no. is specified in
Required equipment on
page 158.
4 pcs, M8x16. Tightening
torque: 24 Nm.

© Copyright 2004-2010 ABB. All rights reserved.

160 3HAC022032-001 Revision: H

 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

A Wrist bracket
B Upper arm bracket
C Front and rear cable holders
D Plastic hose

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Customer connection axis 3HAC 8820-1 Includes signal/power cabling,
4 necessary brackets, holders
etc.
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
© Copyright 2004-2010 ABB. All rights reserved.

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.

Continues on next page

3HAC022032-001 Revision: H 161
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.

Step Action Info/Illustration

1.

DANGER!
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.
2. Remove the wrist bracket and the upper arm Shown in the figure Location of
bracket from the upper arm. signal cabling, upper arm on page
161.
3. Remove the front and rear cable holders from Shown in the figure Location of
the tube shaft. signal cabling, upper arm on page
161.
4. Disconnect the connectors at the rear of the
upper arm.

Refitting, signal cabling upper arm

The procedure below details how to refit the signal cabling to the upper arm.

Step Action Note/Illustration

1.

DANGER!
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.

© Copyright 2004-2010 ABB. All rights reserved.

2. Fit transparent protection tape to the narrow
part of the tube shaft. Remove dirt and grease
from the surface first!
3. Move axis 4 to its calibration position (0°).
4. Refit the wrist bracket to the upper arm. Location of the bracket is shown in
the figure Location of signal
cabling, upper arm on page 161.

xx0300000193

• A: 2 pcs, M8x12.

Continues on next page

162 3HAC022032-001 Revision: H
 4 Repair
4.4.5. Replacement of signal cabling, upper arm (option 042)

Continued

Step 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 161.

xx0300000194

• B: 3pcs, M8x12.
6. Slowly rotate axis 4 clockwise to its stop
position.
Constantly check that the cables are not fully
extended!
Note! If the cables gets fully extended, stop the
rotation and let out more cable from the rear
cable holder. This is done by loosening the grey
holders and pushing ot the cables by hand.
7. Complete the rotation.
Note! Do not tighten the rear cable holder,
leave it open!
8. First fit the front cable holder around the tube
shaft.
Run the black plastic hose through the foot of
the holder.
Fit the rear cable holder around the tube shaft
in the same way.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000197

• A: Plastic hose
• B: Cable holder
Also see the figure Location of
signal cabling, upper arm on page
161.

Continues on next page

3HAC022032-001 Revision: H 163
4 Repair
4.4.5. Replacement of signal cabling, upper arm (option 042)

Continued

Step 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!
• the cables and air hose must not touch
any moving parts of the arm!
• the fixing rings must always slide
smoothly with no excessive pulling!
10. Adjust the length of the cables by pushing and
pulling the cables through the inner holders,
which are still loose.
Note! When axis 4 is moving, no stretching of
the cables should be felt.
11. Tighten the holders by hand. Do not use tools.
12. Reconnect the connectors at the rear end of the
upper arm.
13. Connect the air hose.
14. Secure the cables and air hose together with
cable straps above the motors.
15.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on page
© Copyright 2004-2010 ABB. All rights reserved.
39.

164 3HAC022032-001 Revision: H

 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.

Required equipment

Equipment, etc. Art. no. Note

Standard toolkit - The content is defined in
the section Standard toolkit
on page 275.
Measuring tool, play 3HAB 1611-6
(IRB 4400/45, /60, /L30, /S and IRB 4450S)
Measuring tool, play 3HAB 6337-1
(IRB 4400/L10)
Other tools and procedures may be required. These procedures include
See references to these procedures in the references to the tools
step-by-step instructions below. required.

Measurement, axis 5
The procedure below details how to measure the play of axis 5.

NOTE!
The measuring tool and measuring values differ depending on robot version!

Action Info
1.
© Copyright 2004-2010 ABB. All rights reserved.

DANGER!
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.
2. Move the robot to calibration position and
turn the axis 4 90°.
3. Fit the measuring tool, play to the turning Art. no. is specified in Required
disk. equipment on page 165.

Continues on next page

3HAC022032-001 Revision: H 165
4 Repair
4.4.6. Measuring the play, axis 5

Continued

Action Info
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 4400/45, /

60, /L30, /S and IRB 4450S:
• A: Measuring tool, play
• B: 100mm
• C: 140mm
• F: 200N
Values for robot version IRB 4400/L10:
• A: Measuring tool, play
• B: 140mm
• C: 85mm
• F: 40N
5. Remove the load and set the dial indicator
to zero.

© Copyright 2004-2010 ABB. All rights reserved.

Continues on next page

166 3HAC022032-001 Revision: H
 4 Repair
4.4.6. Measuring the play, axis 5

Continued

Action Info
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:
• A: Measuring tool, play
• B: 100mm
• C: 140mm
• F: 200N
Values for robot version IRB 4400/L10:
• A: Measuring tool, play
• B: 140mm
• C: 85mm
• F: 40N
7. Remove the load and measure the play The maximum play allowed at the given
by reading the dial indicator. distance from the center of axis 5 is, for
robot version
• IRB 4400/45, /60, /L30, /S and IRB
4450S: 0.20mm
• IRB 4400/L10: 0.08mm.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 167

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.

Required equipment

Equipment Art. no. Note

Standard toolkit - The content is defined in the
section Standard toolkit on page
275.
Measuring tool, play 3HAB 1611-6
(IRB 4400/45, /60, /L30, /S and IRB
4450S)
Measuring tool, play 3HAB 6337-1
(IRB 4400/L10)
Other tools and procedures may be These procedures include
required. See references to these references to the tools required.
procedures in the step-by-step instruc-
tions below.

Measurement, axis 6
The procedure below details how to measure the play in axis 6.
NOTE!
The measuring tool and measuring values differ depending on robot version!

Action Info
1.

DANGER! © Copyright 2004-2010 ABB. All rights reserved.

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.
2. Fit the measuring tool, play to the turning Art. no. is specified in Required equipment
disk. on page 168.

Continues on next page

168 3HAC022032-001 Revision: H
 4 Repair
4.4.7. Measuring the play, axis 6

Continued

Action Info
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

Values for robot versions IRB 4400/45, /

60, /L30, /S and IRB 4450S:
• A: Measuring tool, play
• B: 100mm
• m: 20 kg
Values for robot version IRB 4400/L10:
• A: Measuring tool, play
• B: 140mm
• m: 10 kg
4. Apply load F in one direction.

NOTE!
Different load and distances for the
different robot versions, as specified to
the right!
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000189

Values for robot version IRB 4400/45, /60,

/L30, /S and IRB 4450S:
• A: Measuring tool, play
• B: 100mm
• C: 100mm
• F: 100N
Values for robot version IRB 4400/L10:
• A: Measuring tool, play
• B: 100mm
• C: 150mm
• F: 40N
5. Remove the load and set the dial
indicator to zero.

Continues on next page

3HAC022032-001 Revision: H 169
4 Repair
4.4.7. Measuring the play, axis 6

Continued

Action Info
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:
• A: Measuring tool, play
• B: 100mm
• C: 100mm
• F: 100N
Values for robot version IRB 4400/L10:
• A: Measuring tool, play
• B: 100mm
• C: 150mm
• F: 40N
7. Remove the load and measure the play The maximum play allowed at the given
by reading the dial indicator. distance (B) from the center of axis 6 is, for
robot version:
• IRB 4400/45, /60, /L30, /S and IRB
4450S: 0.15mm
• IRB 4400/L10: 0.2mm.

© Copyright 2004-2010 ABB. All rights reserved.

170 3HAC022032-001 Revision: H

 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 in
the Product manual, reference information.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000141

A Lower arm
B Attachment screws and friction washers, lower arm
C Calibration plate, axis 2
D Damper
E Parallel arm
Continues on next page
3HAC022032-001 Revision: H 171
4 Repair
4.5.1. Replacement of lower arm

Continued

F V-ring between lower arm and gearbox axis 3

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Lower arm 3HAC 5955-1
(IRB 4400/45, /60, /L10,
/L30)
Lower arm 3HAC 5956-1
(IRB 4400FS)
Lower arm 3HAC 025476-
(IRB 4450S) 001
V-ring 3HAB 3773-11 2 pcs
On both sides of the lower arm,
in the frame.
Grease 3HAB 3537-1 Used to grease sealings and
bearings.
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the step-
by-step instructions
below.
Calibration Pendulum General calibration information
Instruction is included in the section
Calibration information on
page 247.

© Copyright 2004-2010 ABB. All rights reserved.

Removal, lower arm
The procedure below details how to remove the lower arm from the robot.

Step Action Info/Illustration

1.

DANGER!
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.
2.

CAUTION!
The lower arm weighs 68 kg! All lifting
equipment used must be sized accordingly!

Continues on next page

172 3HAC022032-001 Revision: H
 4 Repair
4.5.1. Replacement of lower arm

Continued

Step Action Info/Illustration

3. Remove the cabling down to axis 1. Detailed in section Removal of cable
harness, axes 4-6.
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 183.
7. Remove the parallel arm. Detailed in section Replacement of
parallel arm / Replacement of bearing
on page 179.
8. Remove the attachment screws and friction Shown in the figure Location of lower
washers, lower arm. arm on page 171.
9. Remove the lower arm from the manipula-
tor.

Refitting, lower arm

The procedure below deatails how to refit the lower arm to the robot.

Step Action Info/Illustration

1.

DANGER!
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.
2.

CAUTION!
© Copyright 2004-2010 ABB. All rights reserved.

The lower arm weighs 68 kg! All lifting equipment

used must be sized accordingly!
3. Move the damper and the calibration plate from the Part no. is specified in
old to the new lower arm. Required equipment on
page 172
4. Check and grease both V-rings in the frame. Replace Part no. is specified in
if damaged. Required equipment on
page 172
5. Lift the lower arm and lower it into mounting position.
Make sure both V-rings stay seated properly!
6. Refit the lower arm to the gearbox axis 2 with 10 pcs. M16x55. Tightening
attachment screws and friction washers, lower arm. torque: 260 Nm.
Shown in the figure Location
of lower arm on page 171
7. Grease the bearing seating of the parallel arm in the
lower arm, to prevent clicking during operation.

Continues on next page

3HAC022032-001 Revision: H 173
4 Repair
4.5.1. Replacement of lower arm

Continued

Step Action Info/Illustration

8. Refit the parallel arm. Detailed in section Refitting,
parallel arm/bearing on page
181
9. Refit the balancing device. Detailed in section Refitting
of balancing device on page
188
10. Refit the upper arm. Detailed in section Refitting,
upper arm on page 147
11. Refit the cabling. Detailed in section Refitting,
cabling axes 4-6 on page
137
12. Recalibrate the robot! Calibration is detailed in a
separate calibration manual
enclosed with the calibration
tools.
General calibration
information is included in the
section Calibration
information on page 247.
13.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may
cause injury or damage! on page 39.

© Copyright 2004-2010 ABB. All rights reserved.

174 3HAC022032-001 Revision: H

 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 in
the Product manual, reference information.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000117

A Tie rod
B Attachment screw
C Washer
D O-ring
E Sealing, outside
F Spherical roller bearing
G Sealing, inside

Continues on next page

3HAC022032-001 Revision: H 175
4 Repair
4.5.2. Replacement of tie rod

Continued

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
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
rod is to be refitted.
Locking liquid Loctite 243
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
Puller tool 2 pcs
Used to pull out the tie rod
alternately at the upper and
lower end if the tie rod.
Press tool 3HAB 1598-1 Used to press in the
spherical roller bearing.
Press tool, p-arm 3HAB 1529-1 2 pcs.
Used to press on the tie rod
alternately at the upper and
lower end of the tie rod.
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.
Calibration Pendulum General calibration

© Copyright 2004-2010 ABB. All rights reserved.

Instruction information is included in
the section Calibration
information on page 247.

Removal, tie rod

The procedure below details how to remove the tie rod from the robot.

Step Action Info/Illustration

1.

DANGER!
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.
2. Lock the upper arm in a horizontal position with help
of a crane or similar.

Continues on next page

176 3HAC022032-001 Revision: H
 4 Repair
4.5.2. Replacement of tie rod

Continued

Step Action Info/Illustration

3. Remove the two attachment screws. Shown in the figure Location
of tie rod on page 175.
4. Remove the two washers, o-rings and sealings, Shown in the figure Location
outside from the tie rod. of tie rod on page 175.
5. Insert a screw in each center, to be used as a support.
6. Use two puller tools to pull out the tie rod, one at the
upper and lower end.
Pull alternately at the upper end and at the lower end
with the puller tools!
7. Remove the bearings if they are to be replaced. The part no. for new
bearings is specified in
section Refitting of tie rod.

Refitting, tie rod

The procedure below details how to refit the tie rod on to the robot.

Step Action Info/Illustration

1.

DANGER!
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.
2. If the bearings are to be replaced, fit new spherical Part/Art. no. is specified in
roller bearings and new sealings, inside to the tie rod. Required equipment on
Use the press tool. page 176
3. Lift the tie rod to its mounting site. Make sure the tie
rod is refitted with the correct end up!
4. Grease the shaft on the robot and refit the tie rod on Art. no. is specified in
to the robot using two press tolls for p-arm. Required equipment on
© Copyright 2004-2010 ABB. All rights reserved.

Press alternately at the upper and lower end with the page 176
press tools!
5. Fit the sealings, outside to the tie rod. Part no. is specified in
Required equipment on
page 176
6. Fit the o-rings to the tie rod. Part no. is specified in
Required equipment on
page 176
7. Refit the washers and attachment screws using Shown in the figure Location
locking liquid. of tie rod on page 175
Locking liquid is specified in
Required equipment on
page 176

Continues on next page

3HAC022032-001 Revision: H 177
4 Repair
4.5.2. Replacement of tie rod

Continued

Step 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 the
section Calibration
information on page 247.
9.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may
cause injury or damage! on page 39.

© Copyright 2004-2010 ABB. All rights reserved.

178 3HAC022032-001 Revision: H

 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.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000128

A Parallel arm
B Attachment screw
C Washer
D V-ring on parallel arm
E Bearing
F Sealing

Continues on next page

3HAC022032-001 Revision: H 179
4 Repair
4.5.3. Replacement of parallel arm / Replacement of bearing

Continued

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
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.
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
Lifting tool 3HAB 1412-1 Used to lift the parallel arm.
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.
Calibration Pendulum General calibration
Instruction information is included in the
section Calibration
information on page 247.

Removal, parallel arm/bearing

The procedure below details how to remove the parallel arm from the robot during repair
work. It also details how to remove the bearing from the parallel arm in order to replace it.
CAUTION!
Caution!
The parallel arm weighs 70 kg (robot version IRB 4400/45 and IRB 4450S) or 115 kg (robot
version IRB 4400/60, IRB 4400/L30, IRB 4400/L10, IRB 4400/S)! All lifting equipment
used must be dimensioned accordingly!
© Copyright 2004-2010 ABB. All rights reserved.
Step Action Info/Illustration
1.

DANGER!
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.
2. Remove the tie rod. Detailed in Replacement of tie rod on
page 175.
3. Fit the lifting tool to the parallel arm. Art. no. is specified in Required
Unload the arm with a crane. equipment on page 180.

Continues on next page

180 3HAC022032-001 Revision: H
 4 Repair
4.5.3. Replacement of parallel arm / Replacement of bearing

Continued

Step 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.
6. Lift away the parallel arm from the robot.
7. If they are to be replaced, remove the
bearing and sealings from the parallel
arm.

Refitting, parallel arm/bearing

The procedure below details how to refit the parallel arm on to the robot during repair work.
It also details how to fit a new bearing to the parallel arm as replacement.
CAUTION!
Caution!
The parallel arm weighs 70 kg (robot version IRB 4400/45 and IRB 4450S) or 115 kg (robot
version IRB 4400/60, IRB 4400/L30, IRB 4400/L10, IRB 4400/S)! All lifting equipment
used must be dimensioned accordingly!

Step Action Info/Illustration

1.
© Copyright 2004-2010 ABB. All rights reserved.

DANGER!
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.
2. Fit the new V-ring to the parallel arm. Part no. is specified in Required
equipment on page 180
3. If the bearing is to be changed: Part no. is specified in Required
• Heat the new groove ball bearing equipment on page 180
to 170°C.
• Fit the bearing to the parallel arm.
If the old bearing is kept:
• Grease the bearing.
4. Fit the sealing ring to the bearing. Part no. is specified in Required
equipment on page 180

Continues on next page

3HAC022032-001 Revision: H 181
4 Repair
4.5.3. Replacement of parallel arm / Replacement of bearing

Continued

Step 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,
reference information, before fitting.
6. Move the upper arm to a horizontal Detailed in section Refitting, tie rod on
position with a crane (if not already page 177
positioned horizontal) and refit the tie
rod.
7. Reposition the cabling and tighten the
cable attachment screws.

xx0300000127

8. Recalibrate the robot! Calibration is detailed in a separate

calibration manual enclosed with the
calibration tools.
General calibration information is
included in the section Calibration
information on page 247.
9.

DANGER!
Make sure all safety requirements are
met when performing the first test run.
© Copyright 2004-2010 ABB. All rights reserved.
These are further detailed in the section
DANGER - First test run may cause
injury or damage! on page 39.

182 3HAC022032-001 Revision: H

 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 in
the Product manual, reference information.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000100

A Balancing device
B Bracket
C Attachment screws, bracket (M12x50)
D Press out hole
E Front screws
F Fork
G End part of shaft

Continues on next page

3HAC022032-001 Revision: H 183
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
(IRB 4400/45, /60, / 3HAC 3702-1
L10, /L30 Includes cylindrical roller
bearing 3HAC 4334-2
Includes front screws 3HAC
6456-1
Balancing device 3HAC 15083-2 Includes balancing device
(IRB 4400/FS) 3HAC 3738-1
Includes cylindrical roller
bearing 3HAC 4334-2
Includes front screws 3HAC
6456-1
Balancing device 3HAC025477-001
(IRB 4450S)
Sealing ring with dust 3HAB 3701-26
lip
Grease 3HAC 3537-1 Used to lubricate:
the bearings at the balancing
device brackets (min. 500
ml. in each bearing)
the sealing at the balancing
device brackets
the bearing at the balancing
device fork

Nipple Used to lubricate the bearing

at hte balancing device fork.
The lubrication hole is
dimensioned M10.
Standard toolkit 3HAC 17594-1 The contents are defined in
section Standard toolkit in
© Copyright 2004-2010 ABB. All rights reserved.
the Product manual,
reference information.
Securing front screws M10x40H
H= threaded to the head.
Used to unload the
balancing device before
removal.
Press tool, bearing 3HAC 5465-1 Used to fit the cylidrical roller
bearings and the sealings
into the brackets.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the step-
by-step instructions
below.

Continues on next page

184 3HAC022032-001 Revision: H
 4 Repair
4.6.1. Replacement of balancing device

Continued

Removal, balancing device

The procedure below details how to remove the balancing device.

Step Action Info/Illustration

1.

WARNING!
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!
2.

DANGER!
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.
3.

CAUTION!
The complete arm system weighs 232 kg!
All lifting equipment used must be sized
accordingly!
4. Move the manipulator to the calibration
position, as shown in the figure to the
right.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000088

• A: Approximately 2º

Continues on next page

3HAC022032-001 Revision: H 185
4 Repair
4.6.1. Replacement of balancing device

Continued

Step 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

of balancing device on page 183.
6. Unload the balancing device by replacing
the two front screws (A) with two securing
front screws.
Unload the device level by fastening the
securing screws parallel with each other.
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000095

Dimension specified in Required

equipment on page 184!
7. Check that the piston is unloaded by
moving it manually.

Continues on next page

186 3HAC022032-001 Revision: H
 4 Repair
4.6.1. Replacement of balancing device

Continued

Step 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 183!
of the balancing device (A), seen from
above.

xx0300000098

9. Remove the bracket from the frame by Shown in the figure Location of
pressing it out using a M10x30 screw in balancing device on page 183!
the press out hole.
10. Remove the balancing device by pushing
it to the side.
Note!
The balancing device weighs 50 kg!
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000099

11. If the balancing device is to be replaced

with a new device, the bracket on the right
side must be removed and fitted to the
new device.

Continues on next page

3HAC022032-001 Revision: H 187
4 Repair
4.6.1. Replacement of balancing device

Continued

Refitting of balancing device

The procedure below details how to refit the balancing device.

Step Action Info/Illustration

1.

WARNING!
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!
2.

DANGER!
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.
3.

CAUTION!
The complete arm system weighs 232 kg!
All lifting equipment used must be sized
accordingly!
4. Fit the cylindrical roller bearings and The procedure is detailed in Fitting of
sealings to the balancing device and cylindrical roller bearing on page 190
brackets if Part no. is specified in Required
• the balancing device is a new spare equipment on page 184
part
• the old bearings/sealings are
damaged.
5. Lift the balancing device to its mounting If the balancing device is a new spare © Copyright 2004-2010 ABB. All rights reserved.
position. part, it must be unloaded as described
in Removal, balancing device on page
185
6. Fit the balancing device to the left bracket Shown in the figure Location of
and put the fork into correct position. balancing device on page 183
7. Refit the right bracket with attachment 4 pcs: M12x50, tightening torque: 82
screws, bracket . Nm
Shown in the figure Location of
balancing device on page 183
8. Refit the original protection screws in the 2 pcs. MC6S M10x12 8.8 fzb.
press out holes in both the brackets. Shown in the figure Location of
balancing device on page 183

Continues on next page

188 3HAC022032-001 Revision: H
 4 Repair
4.6.1. Replacement of balancing device

Continued

Step 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. Use a nipple!
• Refit the two stop screws.
• Refit the plate with one screw M8x16
(C). This plate secures the bushing
(D) is held in its position.

xx0300000089

A: Securing screws (2 pcs)

B: Stop screws, M10 x 40 (2 pcs)
C: Plate and screw M8 x 16 (1 pc)
D: Bushing
10. Before restoring the balancing device, The fork is shown in the figure
check that: Location of balancing device on page
• the fork is in position 183
• the fork does not cover the
© Copyright 2004-2010 ABB. All rights reserved.

lubrication holes of the shaft!

11. Restore the balancing device by removing
the replacement front screws (A) and
refitting the original protection front screws.

xx0300000095

2 pcs: MC6S M10x12 8.8 fzb

12. Refit the fork to the shaft in the lower arm, Shown in the figure above in Refitting
by refitting the two securing screws (A) at of balancing device on page 188
the fork of the balancing device.
Make sure that the fork does not cover the
lubrication holes of the shaft!

Continues on next page

3HAC022032-001 Revision: H 189
4 Repair
4.6.1. Replacement of balancing device

Continued

Step Action Info/Illustration

13.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These
are further detailed in the section DANGER
- First test run may cause injury or damage!
on page 39.

Fitting of cylindrical roller bearing

The procedure below details how to fit the cylindrical roller bearings onto the balancing
device shaft and into the frame brackets.

Step Action Info/Illustration

1. Fit the inner ring of the bearing onto both end parts of Shown in the figure Location
the balancing devices shaft . of balancing device on page
183
2. Fit the outer ring of the bearing into both brackets with Art. no. is specified in
a press toll, bearing. Required equipment on
page 184
3. Fit the sealing ring with dust lip with the same, but Part no. is specified in
turned, press tool, bearing. Required equipment on
page 184
4. Lubricate the bearing and the sealing with grease. Art. no. and amount
specified in Required
equipment on page 184
5.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may © Copyright 2004-2010 ABB. All rights reserved.
cause injury or damage! on page 39.

190 3HAC022032-001 Revision: H

 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

A Rear cover plate

Different versions, serial measurement unit

There are two versions of the serial measurement unit. They are compatible but designed
differently, as shown in the figure below.
Note! The battery pack is not compatible between the versions!
© Copyright 2004-2010 ABB. All rights reserved.

xx0300000105

(1) Old version of serial measurement unit

(2) New version of serial measurement unit
A R2.SMB
B R2.FB4-6
C R2.FB1-3
D Fastening plate
E Battery pack

Continues on next page

3HAC022032-001 Revision: H 191
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 3HAC 17395-1
version
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
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.
Circuit Diagram See the chapter Circuit
diagram.

Removal, serial measurement unit

The procedure below details how to remove the serial measurement unit.

Step Action Note/Illustration

1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!

© Copyright 2004-2010 ABB. All rights reserved.

For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2.

esd

WARNING!
The unit is sensitive to ESD. Before handling the unit
please read the safety information in the section
WARNING - The unit is sensitive to ESD! on page 40
3. Remove the rear cover plate from the base. Shown in the figure Location
of serial measurement unit
on page 191.
4. Cut all the straps.
5. Unscrew the nuts that attaches the serial
measurement unit inside the base.
6. Remove the serial measurement unit.

Continues on next page

192 3HAC022032-001 Revision: H
 4 Repair
4.6.2. Replacement of serial measurement unit

Continued

Step Action Note/Illustration

7. Remove the connectors from the board. The connectors are shown in
the figure Different versions,
serial measurement unit on
page 191.

Refitting, serial measurement unit

The procedure below details how to refit the complete serial measurement unit.

Step Action Note/Illustration

1.

DANGER!
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.
2.

esd

WARNING!
The unit is sensitive to ESD. Before handling the unit
please read the safety information in the section
WARNING - The unit is sensitive to ESD! on page 40
3. Refit the connectors to the serial measurement unit. Art. no. is specified in
Required equipment on
page 192.
The connectors are shown in
the figure Different versions,
serial measurement unit on
page 191.
© Copyright 2004-2010 ABB. All rights reserved.

4. Refit the serial measurement unit inside the base

using nuts.
5. Strap the cables.
6. Refit the rear cover plate on the base. Shown in the figure Location
of serial measurement unit
on page 191.
7. Recalibrate the robot! Calibration is detailed in a
separate calibration manual
enclosed with the calibration
tools.
General calibration
information is included in the
section Calibration
information on page 247.

3HAC022032-001 Revision: H 193

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. (The figure shows the IRB 4400.)
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0300000106

A Rear cover plate

Connectors on pushbutton unit

The connectors X8, X9 and X10 are placed on the pushbutton unit as shown in the figure
below.

xx0300000201

Required equipment © Copyright 2004-2010 ABB. All rights reserved.

Spare part
Equipment, etc. Art. no. Note
no.
Pushbutton unit 3HAC 0017-1
Standard toolkit 3HAC 17594-1 The content is defined in
the section Standard toolkit
on page 275.
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.
Calibration Pendulum Art. no. is specified in
Instruction section Document
references on page 273 in
part 2 of the Product
manual.
Continues on next page
194 3HAC022032-001 Revision: H
 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.

Step Action Info/Illustration

1.

DANGER!
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.
2.

esd

WARNING!
The unit is sensitive to ESD. Before handling the unit
please read the safety information in the section
WARNING - The unit is sensitive to ESD! on page 40
3. Secure the robot by moving...
• the lower arm to one of its end positions
• the upper arm to its end position.
4. Remove the rear cover plate. Shown in the figure Location
of pushbutton unit on page
194.
5. Remove the connectors X8, X9 and X10 from the Shown in the figure
pushbutton unit. Connectors on pushbutton
unit on page 194.
6. Remove the pushbutton unit by removing its
attachment screws.
© Copyright 2004-2010 ABB. All rights reserved.

Continues on next page

3HAC022032-001 Revision: H 195
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.

Step Action Note/Illustration

1.

DANGER!
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.
2.

esd

WARNING!
The unit is sensitive to ESD. Before handling the unit
please read the safety information in the section
WARNING - The unit is sensitive to ESD! on page 40
3. Refit the new pushbutton unit with its attachment Part no. is specified in
screws. Required equipment on
page 194.
4. Refit the connectors X8, X9 and X10 to the Shown in the figure
pushbutton unit. Connectors on pushbutton
unit on page 194.
5. Refit the rear cover plate to the base of the robot. Shown in the figure Location
of pushbutton unit on page
194.
6. Recalibrate the robot! Calibration with the
pendulum is detailed in the
Calibration Pendulum
Instruction, enclosed with
the calibration toolkit.
© Copyright 2004-2010 ABB. All rights reserved.
Other calibration is detailed
in section Calibration
information on page 247.
7.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may
cause injury or damage! on page 39.

196 3HAC022032-001 Revision: H

 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 in
the Product manual, reference information.

xx0300000182

A Mechanical stop pin, axis 1

B Set screw

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Mechanical stop, axis 1 3HAB 3647-1
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
© Copyright 2004-2010 ABB. All rights reserved.

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.

Continues on next page

3HAC022032-001 Revision: H 197
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.
WARNING!
If the mechanical stop has been deformed after a hard collision, it must be replaced!

Step Action Info/Illustration

1.

DANGER!
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.
2. Remove the set screw. Shown in the figure in
Location of mechanical stop
pin on page 197.
3. Remove the old mechanical stop pin. Shown in the figure in
Location of mechanical stop
pin on page 197.
4. Refit the new mechanical stop with the set screw. Part no. is specified in
Required equipment on
page 197.
M10x12

© Copyright 2004-2010 ABB. All rights reserved.

198 3HAC022032-001 Revision: H

 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 in
the Product manual, reference information.

xx0300000154

A Motor, axis 1
B Connection box with cover
© Copyright 2004-2010 ABB. All rights reserved.

C Attachment screws and washers

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Motor unit, axis 1 3HAC 5952-1 Elmo
(IRB 4400/45, /60, /L10, Includes motor pinion.
/L30)
Motor unit, axis 1 3HAC 9841-1 Elmo
(IRB 4400/S) Includes motor pinion.
Motor unit, axis 1 3HAC021724-001 Yaskawa
(IRB 4400/45, /60, /L10 Includes pinion
and IRB 4450S)
Motor unit, axis 1 3HAC021725-001 Yaskawa
(IRB 4400/L30) Includes pinion
Motor unit, axis 1 3HAC021729-001 Yaskawa
(IRB 4400/S) Includes pinion

Continues on next page

3HAC022032-001 Revision: H 199
4 Repair
4.7.1. Replacement of motor, axis 1

Continued

Equipment, etc. Spare part no. Art. no. Note

O-ring, motor 2152 0431-11
Flange sealing 1234 0011-116 Loctite 574
Gasket 3HAC 4432-1 Between the motor and the
connection box.
Replace if damaged!
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
Power supply 24 VDC, 1.5 A
Used in order to release the
brakes.
Measuring toll 3HAB 7887-1 or Choose one of the tools.
3HAB 1408-1
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the step-
by-step instructions
below.
Circuit Diagram See the chapter Circuit
diagram.
Calibration Pendulum General calibration
Instruction information is included in the
section Calibration
information on page 247.

Removal, motor axis 1

The procedure below details how to remove the motor, axis 1.
DANGER!
If a shelf-mounted robot version is not flat mounted, the manipulator can contain a living

© Copyright 2004-2010 ABB. All rights reserved.

force!
Removing the motor from axis 1 may result in movement of the axis, because the brake is
released.
To avoid this, move the robot into normal calibration position or move axis 1 to get the lowest
location of the center of gravity for the upper arm.

Action Info
1.

DANGER!
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.

Continues on next page

200 3HAC022032-001 Revision: H
 4 Repair
4.7.1. Replacement of motor, axis 1

Continued

Action Info
2.

CAUTION!
Whenever parting/mating motor and gearbox,
the gears may be damaged if excessive force is
used!
3. Remove the cover of the connection box. Shown in the figure Location of
motor on page 199.
4. Disconnect all the connectors in the motor.
5. Remove the connection box. Shown in the figure Location of
motor on page 199.
6. Remove the attachment screws and washers of Shown in the figure Location of
the motor. motor on page 199.

NOTE!
Check the position of the motor label before
removing the motor! The motor must be
mounted back at the same position!
7. Remove the motor.

Refitting, motor axis 1

The procedure below details how to refit the motor, axis 1.

Action Info
1.

DANGER!
Turn off all electric power, hydraulic and
© Copyright 2004-2010 ABB. All rights reserved.

pneumatic pressure supplies to the robot!

For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2.

CAUTION!
Whenever parting/mating motor and gearbox,
the gears may be damaged if excessive force is
used!
3.

NOTE!
The motor units from Elmo and Yaskawa are
not compatible!

Continues on next page

3HAC022032-001 Revision: H 201
4 Repair
4.7.1. Replacement of motor, axis 1

Continued

Action Info
4. Check that the assembly surfaces are clean
from paint, lubricant etc.
Make sure that the motor and the gearbox are
not damaged or scratched.
5. Fit the o-ring to the new motor unit. Part no. is specified in Required
equipment on page 199
6. Release the brake of the motor by connecting Connect to connector R3.MP1
the 24 VDC power supply. • +24V: pin 7
• 0V: pin 8.
7. Apply flange sealing to the motor flange. Art. no. is specified in Required
equipment on page 199
8. Place the new motor in the gearbox.
Do not damage the pinion and the gear-wheel!
Note the position of the motor! The motor label
should be mounted in the same position as it
had before removal.
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.

© Copyright 2004-2010 ABB. All rights reserved.

xx0300000155

A: Lower screw
B: Upper screw
C: Pushing direction
10. Adjustment detailed in section
Adjustment of motors, axes 1-3 on
page 214
NOTE!
Adjust the motor before continuing the refitting
procedure!
11. Fit the other two attachment screws and Total 4 pcs. M10x30.
washers. Tightening torque: 60 Nm.
Continues on next page
202 3HAC022032-001 Revision: H
 4 Repair
4.7.1. Replacement of motor, axis 1

Continued

Action Info
12. Check the oil level. Fill with oil if necessary Detailed in section Inspection of oil
levels on page 107
13. Refit the connection box. Part no. is specified in Required
Replace the gaskets if they are damaged! equipment on page 199
14. Reconnect all the connectors.
15. Refit the cover of the connection box.
16. Recalibrate the robot! Calibration is detailed in a separate
calibration manual enclosed with
the calibration tools.
General calibration information is
included in the section Calibration
information on page 247.
17.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on page
39.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 203

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 in
the Product manual, reference information.

xx0300000159

A Motor, axis 2
B Connection box
C Attachment screws and washers

Required equipment © Copyright 2004-2010 ABB. All rights reserved.

Equipment, etc. Spare part no. Art. no. Note

Motor unit, axis 2 3HAC5954-1 Elmo
(IRB 4400 -all versions) Includes pinion
Motor unit, axis 2 3HAC021725-001 Yaskawa
(IRB 4400 - all versions Includes pinion
and IRB 4450S)
O-ring 21520431-11
Flange sealing 12340011-11 Loctite 574
Standard toolkit 3HAC17594-1 The content is defined in the
section Standard toolkit on
page 275.
Power supply 24 VDC, 1,5 A
Used in order to release the
brakes.

Continues on next page

204 3HAC022032-001 Revision: H
 4 Repair
4.7.2. Replacement of motor, axis 2

Continued

Equipment, etc. Spare part no. Art. no. Note

Measuring tool 3HAB7887-1 Choose one of the two tools.
3HAB1408-1
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 instruc-
tions below.
Circuit Diagram See the chapter Circuit
diagram.
Calibration Pendulum General calibration
Instruction information is included in the
section Calibration
information on page 247.

Removal, motor axis 2

The procedure below details how to remove the motor, axis 2.

Action Info
1.

DANGER!
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.
2.

Danger!
© Copyright 2004-2010 ABB. All rights reserved.

Secure the arm system before removing the motor!

The brake is located in the motor and is therefore
released when the motor is removed.
3.

CAUTION!
Whenever parting/mating motor and gearbox, the
gears may be damaged if excessive force is used!
4. Remove the cover of the connection box.
5. Disconnect all the connectors in the motor.
6. Remove the connection box. Shown in the figure Location of
motor on page 204.

Continues on next page

3HAC022032-001 Revision: H 205
4 Repair
4.7.2. Replacement of motor, axis 2

Continued

Action Info
7.

NOTE!
Check the position of the motor label before removing
it. The motor must be mounted in the same position.
8. Remove the attachment screws and washers of the Shown in the figure Location of
motor. motor on page 204.

NOTE!
Oil will start to run out when removing the motor!
9. Remove the motor.

Refitting, motor axis 2

The procedure below details how to refit the motor, axis 2.

Action Info
1.

DANGER!
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.
2.

CAUTION!
Whenever parting/mating motor and

© Copyright 2004-2010 ABB. All rights reserved.

gearbox, the gears may be damaged if
excessive force is used!
3.

NOTE!
The motor units from Elmo and Yaskawa are
not compatible!
4. Check that the assembly surfaces are clean
from paint, lubricant etc.
Make sure that the motor and the gearbox
are not damaged or scratched.
5. Mount the o-ring to the new motor unit. Part no. is specified in Required
equipment on page 204
6. Release the brake of the motor by connecting Connect to connector R3.MP2
the 24 VDC power supply. • +24V: pin 7
• 0V: pin 8
7. Apply flange sealing to the motor flange. Art. no. is specified in Required
equipment on page 204
Continues on next page
206 3HAC022032-001 Revision: H
 4 Repair
4.7.2. Replacement of motor, axis 2

Continued

Action Info
8. Place the new motor in the gearbox.
Do not damage the pinion or the gear wheel!

NOTE!
Check the position of the motor! The motor
label should be mounted in the same position
as it had before the removal.
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.

xx0300000160

A: Upper screw
B: Lower screw
C: Pushing direction
10. Adjustment is detailed in section
Adjustment of motors, axes 1-3 on page
214
NOTE!
Adjust the motor before continuing the
refitting procedure!
11. Fit the other two attachment screws and Shown in the figure Location of motor on
washers. page 204
© Copyright 2004-2010 ABB. All rights reserved.

2 pcs: M10x70
2 pcs: M10x30
Tightening torque: 60 Nm
12. Refill with oil. Detailed in Oil in gearbox unit, axis 1-2-
3 on page 106
13. Refit the connection box. Shown in the figure Location of motor on
page 204
14. Reconnect the connectors.
15. Refit the cover of the connection box.
16. Recalibrate the robot! Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in the section Calibration
information on page 247.

Continues on next page

3HAC022032-001 Revision: H 207
4 Repair
4.7.2. Replacement of motor, axis 2

Continued

Action Info
17.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER -
First test run may cause injury or damage! on
page 39.

© Copyright 2004-2010 ABB. All rights reserved.

208 3HAC022032-001 Revision: H

 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 in
the Product manual, reference information.

xx0300000163

A Motor, axis 3
B Connection box
C Attachment screws and washers, motor
© Copyright 2004-2010 ABB. All rights reserved.

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Motor unit, axis 3 3HAC5954-1 Elmo
(IRB 4400 all versions) Includes pinion
Motor unit, axis 3 3HAC021725-001 Yaskawa
(IRB 4400 all versions and Includes pinion
IRB 4450S)
O-ring 21520431-11
Flange sealing 12340011-116 Loctite 574
Standard toolkit 3HAC17594-1 The content is defined in
the section Standard
toolkit on page 275.
Power supply 24 VDC, 1.5 A
To be used for releasing
the brakes.

Continues on next page

3HAC022032-001 Revision: H 209
4 Repair
4.7.3. Replacement of motor, axis 3

Continued

Equipment, etc. Spare part no. Art. no. Note

Measuring tool 3HAB7887-1 Choose one of the two
3HAB1408-1 tools.
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.
Circuit Diagram See the chapter Circuit
diagram.
Calibration Pendulum General calibration
Instruction information is included in
the section Calibration
information on page 247.

Removal, motor axis 3

The procedure below details how to remove the motor, axis 3.

Action Info
1.

DANGER!
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.
2.

DANGER!
Secure the upper arm system before removing the
motor from axis 3! The brake is located in the motor
© Copyright 2004-2010 ABB. All rights reserved.
and is therefore released when the motor is removed.
3.

CAUTION!
Whenever parting/mating motor and gearbox, the
gears may be damaged if excessive force is used!
4. Remove the cover from the connection box.
5. Disconnect all the connectors in the motor.
6. Remove the connection box from the motor. Shown in the figure Location of
motor on page 209.
7.

NOTE!
Check the position of the motor label before removing
it! The motor must be mounted in the same position.

Continues on next page

210 3HAC022032-001 Revision: H
 4 Repair
4.7.3. Replacement of motor, axis 3

Continued

Action Info
8. Remove the attachment screws and washers, motor. Shown in the figure Location of
motor on page 209.

NOTE!
Oil will start to run out when removing the motor!
9. Remove the motor.

Refitting. motor axis 3

The procedure below details how to refit the motor, axis 3.

Action Info
1.

DANGER!
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.
2.

CAUTION!
Whenever parting/mating motor and
gearbox, the gears may be damaged if
excessive force is used!
3.

NOTE!
The motor units from ELMO and YASKAWA
© Copyright 2004-2010 ABB. All rights reserved.

are not compatible!

4. Check that the assembly surfaces are clean
from paint, lubricant etc.
Make sure that the motor and the gearbox
are not damaged or scratched.
5. Fit the o-ring to the new motor unit. Part no. is specified in Required
equipment on page 209
6. Release the brake of the motor by Connect to connectorR3.MP3
connecting the 24 VDC power supply. • +24V: pin 7
• 0V: pin 8
7. Apply flange sealing to the motor flange. Art. no. is specified in Required
equipment on page 209

Continues on next page

3HAC022032-001 Revision: H 211
4 Repair
4.7.3. Replacement of motor, axis 3

Continued

Action Info
8. Place the new motor in the gearbox.
Do not damage the pinion and the gear
wheel!
NOTE!
Check the position of the motor! The
motor label should be mounted in the
same position as it had before the
removal.
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.

xx0300000160

Motor axis 2, is shown in the figure!

A: Upper screw
B: Lower screw
C: Pushing direction
10. Note! Adjustment is detailed in section
Adjust the motor before continuing the Adjustment of motors, axes 1-3 on page
refitting procedure! 214
11. Fit the other two attachment screws and Shown in figure Location of motor on
washers, motor. page 209
M10x70
M10x30
Tightening torque: 60 Nm
12. Refill with oil. Detailed in Oil in gearbox unit, axis 1-2-3 © Copyright 2004-2010 ABB. All rights reserved.
on page 106
13. Refit the connection box. Shown in the figure Location of motor on
page 209
14. Reconnect the connectors.
15. Refit the cover of the connection box.
16. Recalibrate the robot! Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in the section Calibration
information on page 247.

Continues on next page

212 3HAC022032-001 Revision: H
 4 Repair
4.7.3. Replacement of motor, axis 3

Continued

Action Info
17.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These
are further detailed in the section DANGER
- First test run may cause injury or damage!
on page 39.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 213

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
• Refitting of motor, axis 1
• Refitting of motor, axis 2
• Refitting of motor, axis 3.

Required equipment

Equipment, etc. Art. no. Note

Standard toolkit 3HAC17594-1 The content is defined in the section
Standard toolkit on page 275.
Measuring tool Either Choose one of the tools. They are all
3HAB7887-1 or compatible with the motor.
3HAB1408-1
Power supply 24 VDC, 1.5 A
For releasing the brakes.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-
by-step instructions below.
Circuit Diagram See the chapter Circuit diagram.

Adjustment
The procedure below details how to adjust the motors during refitting.

Action Info
1. Lock the motor brake before mounting the
adjustment tool.
2. Fit the measuring tool to the motor axis. Art. no. is specified in Required © Copyright 2004-2010 ABB. All rights reserved.
equipment on page 214.
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
• +24V: pin 7
• 0V: pin 8.
Axis 3 motor: connect to connector
R3.MP3
• +24V: pin 7
• 0V: pin 8.

Continues on next page

214 3HAC022032-001 Revision: H
 4 Repair
4.7.4. Adjustment of motors, axes 1-3

Continued

Action Info
4. Rotate the motor shaft with the measuring
tool. Measure the torque in both directions
with a spring balance.
A normal torque is 0.6-0.8 Nm (=6-8 N on
radius 100 mm). Torques higher than 0.8 Nm
are not allowed, as they will reduce the
lifetime of the motor and gear.
5. Loosen the lower and upper screws until the
motor can be moved sideways by hand.

NOTE!
The brake must be released in the
motor.
6. Push the motor with one hand against the
gear and tighten the two screws with the
other hand.
1)
7. Measure the torque with the motor shaft in The brake disc is mounted on the
different positions. The torque should be motor shaft with a type of splined
max. 0.1 Nm (on radius 50 mm) more than coupling. Between the splines there is a
measured before. narrow backlash.
If the torque is more,
• slightly loosen the screws a little and
carefully knock the motor in the
opposite direction
• then measure the torque again. NOTE!
Check that the backlash is very limited, by There should always be a backlash, but
moving the tool back and forward in small it should be as minimal as possible.
movements.
When turning the motor shaft, a tick-tack
sound can be heard from the brake disc1).
This should not be mixed up with the
backlash. The difficult part is to find the motor
position where the torque just starts to
increase.
© Copyright 2004-2010 ABB. All rights reserved.

8. Remove the measuring tool.

9. Disconnect the brake release voltage.
10. Continue refitting the motor. Refitting, motor, axis 1
Refitting, motor, axis 2
Refitting, motor, axis 3

3HAC022032-001 Revision: H 215

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.
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0300000164

A Motor unit, axis 4

B Motor unit, axis 5

© Copyright 2004-2010 ABB. All rights reserved.

C Motor unit, axis 6
D Attachment screws and washers, motor
E Connection box

Required equipment

Equipment, etc. Art. no. Note

Standard toolkit 3HAC17594-1 The content is defined in the section
Standard toolkit on page 275.
Other tools and procedures may These procedures include
be required. See references to references to the tools required.
these procedures in the step-by-
step instructions below.
Circuit Diagram See the chapter Circuit diagram.

Continues on next page

216 3HAC022032-001 Revision: H
 4 Repair
4.7.5. Removal of motor, axes 4, 5 and 6

Continued

Removal, motor axes 4, 5 and 6

The procedure below details how to remove the motors of axes 4, 5 and 6.

Action Info
1.

DANGER!
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.
2.

DANGER!
Secure the arm system before removing any motor!
The brake is located in the motor and is therefore
released when the motor is removed!
3.

CAUTION!
Whenever parting/mating motor and gearbox, the
gears may be damaged if excessive force is used!
4. Drain the oil from the gearbox. Draining is detailed in sections:
• Oil change, gearbox
axis 4 on page 111.
• Oil change, gearbox
axis 5 and 6 (all robot
versions except IRB
4400/L10) on page 114
• Oil change, gearbox
axis 5 and 6 (IRB 4400/
L10 only) on page 117.
© Copyright 2004-2010 ABB. All rights reserved.

5. Remove the cover of the connection box.

6. Disconnect all the connectors in the connection box.
7. Remove the connection box. Shown in the figure Location of
motors on page 216.
8.

NOTE!
Check the position of the motor before removing it.
The motor must be mounted back at the same
position.
9. Remove the attachment screws and washers, motor. Shown in the figure Location of
motors on page 216.
10. Remove the motor.

3HAC022032-001 Revision: H 217

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 in
the Product manual, reference information.

xx0300000164

A Motor unit, axis 4

B Motor unit, axis 5
C Motor unit axis 6 © Copyright 2004-2010 ABB. All rights reserved.
D Attachment screws and washers, motor
E Connection box

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Motor unit, axis 4 3HAC10603-1 Elmo
(IRB 4400 all versions) Includes pinion.
Motor unit, axis 4 3HAC021726-001 Yaskawa
(IRB 4400/45, /60, /L30, /S Includes pinion
and IRB 4450S)
Motor unit, axis 4 3HAC021962-001 Yaskawa
(IRB 4400/L10) Includes pinion
O-ring 21522012-426

Continues on next page

218 3HAC022032-001 Revision: H
 4 Repair
4.7.6. Refitting of motor, axis 4

Continued

Equipment, etc. Spare part no. Art. no. Note

Gasket 3HAC3676-1 3 pcs
Between the motors and
the connection box.
Replace if damaged.
Standard toolkit 3HAC17594-1 The content is defined in
the section Standard
toolkit on page 275.
Measuring tool 3HAB1409-1
Power supply 24VDC, 1.5A
Used to release the
brake of the motor.
Other tools and These procedures
procedures may be include references to the
required. See references tools required.
to these procedures in the
step-by-step instructions
below.
Circuit Diagram See the chapter Circuit
diagram.
Calibration Pendulum Art. no. is specified in
Instruction section Document
references on page
273in part 2 of the
Product manual.

Refitting, motor axis 4

The procedure below details how to refit the motor, axis 4.

Action Info
1.
© Copyright 2004-2010 ABB. All rights reserved.

DANGER!
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.
2.

CAUTION!
Whenever parting/mating motor and gearbox,
the gears may be damaged if excessive force
is used!
3.

NOTE!
The motor unit from ELMO and YASKAWA
are not compatible!

Continues on next page

3HAC022032-001 Revision: H 219
4 Repair
4.7.6. Refitting of motor, axis 4

Continued

Action Info
4. Check that the assembly surfaces are clean
from paint, lubricant etc.
Make sure that the motor and the gearbox are
not damaged or scratched.
5. Fit the o-ring to the new motor unit. Part no. is specified in Required
equipment on page 218.
6. Fit the measuring tool to the rear of the motor. Art. no. is specified in Required
equipment on page 218.
7. Release the brake of the motor by connecting Connect to connector R3.MP4
the 24 VDC power supply. • +24V: pin 7
• 0V: pin 8.
8. Place the new motor unit in the gearbox.
Do not damage the pinion or the gear wheel.
9. Find the position with the least play by turning
the motor shaft 10 revolutions, noting
changes in play as you turn the motor.
10. Push the motor in a radial direction so that the
play is minimal within one motor revolution
without the gear "chewing".
11. Refit the motor with its attachment screws Shown in the figure Location of motor on
and washers, motor. page 218.
4 pcs, M6x25. Tightening torque: 15
Nm.
12. Refill with oil, if drained. Detailed in section Oil change, gearbox
axis 4 on page 111.
13. Check the position of the three gaskets, Part no. is specified in Required
located between the motors and the equipment on page 218.
connection box. Replace them if damaged.
14. Refit the connection box. Shown in the figure Location of motor on
Make sure the gaskets are seated properly! page 218.
15. Reconnect all the connectors.
16. Refit the cover to the connection box.
17. Recalibrate the robot! Calibration is detailed in a separate © Copyright 2004-2010 ABB. All rights reserved.
calibration manual enclosed with the
calibration tools.
General calibration information is
included in the section Calibration
information on page 247.
18.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on page
39.

220 3HAC022032-001 Revision: H

 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 in
the Product manual, reference information.

xx0300000164

A Motor unit, axis 4

B Motor unit, axis 5
© Copyright 2004-2010 ABB. All rights reserved.

C Motor unit, axis 6

D Attachment screws and washers, motor
E Connection box

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Motor unit, axis 5 3HAC10603-1 Elmo
(IRB 4400/45, /60, /L30, Includes pinion.
/S)
Motor unit, axis 5 3HAC10605-1 Elmo
(IRB 4400/L10) Includes pinion.
Motor unit, axis 5 3HAC021726-001 Yaskawa
(IRB 4400/45, /60, /L30, Includes pinion
/S and IRB 4450S)
Motor unit, axis 5 3HAC021962-001 Yaskawa
(IRB 4400/L10) Includes pinion

Continues on next page

3HAC022032-001 Revision: H 221
4 Repair
4.7.7. Refitting of motor, axis 5

Continued

Equipment, etc. Spare part no. Art. no. Note

O-ring 21522012-426
Gasket 3HAC3676-1 3 pcs
Between the motor and the
connection box.
Replace if damaged.
Standard toolkit 3HAC17594-1 The content is defined in the
section Standard toolkit on
page 275.
Measuring tool 3HAB1409-1
Power supply 24VDC, 1.5A
2 pcs, used to release the
brakes in the motors for axes
4 and 5.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the step-
by-step instructions
below.
Circuit Diagram See the chapter Circuit
diagram.
Calibration Pendulum Art. no. is specified in
Instruction section Document
references on page 273in
part 2 of the Product manual.

Refitting, motor axis 5

The procedure below details how to refit the axis 5 motor.

Action Info
1.
© Copyright 2004-2010 ABB. All rights reserved.

DANGER!
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.
2.

CAUTION!
Whenever parting/mating motor and gearbox, the
gears may be damaged if excessive force is used!
3.

NOTE!
The motor units from ELMO and YASKAWA are
not compatible!

Continues on next page

222 3HAC022032-001 Revision: H
 4 Repair
4.7.7. Refitting of motor, axis 5

Continued

Action Info
4. Check that the assembly surfaces are clean from
paint, lubricant etc.
Make sure that the motor and the gearbox are not
damaged or scratched.
5. Fit the o-ring into the new motor. Part no. is specified in Required
equipment on page 221.
6. Fit the measuring tool to the rear of the motor. Art. no. is specified in Required
equipment on page 221.
7. Release the brakes in the motors for axes 4 and 5, Connect to connector R3.MP4/
by connecting the 24 VDC power supply. MP5
• +24V: pin 7
• 0V: pin 8.
8. Place the new motor unit in the gearbox.
Do not damage the pinion or the gear wheel.
9. Find the position of least play by turning the
outgoing shaft for axis 4 in intervals of 90°, one
revolution in all, to locate the area where the play
for the motor axis 5 is the smallest.
10. Turn the motor for axis 5 one full revolution at a
time, five revolutions in all. Find the smallest play
within this range.
11. Push the motor in a radial direction so that the play
is minimal within one motor revolution without the
gear "chewing".
12. Refit the motor with its attachment screws and Shown in the figure Location of
washers, motor. motor on page 221.
4 pcs, M6x25. Tightening torque:
15 Nm.
13. Refill with oil, if drained. Detailed in section:
• Oil change, gearbox axis 5
and 6 (all robot versions
except IRB 4400/L10) on
page 114
© Copyright 2004-2010 ABB. All rights reserved.

• Oil change, gearbox axis 5

and 6 (IRB 4400/L10 only)
on page 117.
14. Check the position of the three gaskets, located Part no. is specified in Required
between the motors and the connection box. equipment on page 221.
Replace them if damaged.
15. Refit the connection box. Shown in the figure Location of
Make sure the gaskets are seated properly! motor on page 221.
16. Reconnect all the connectors.
17. Refit the cover on the connection box.
18. Recalibrate the robot! Calibration is detailed in a
separate calibration manual
enclosed with the calibration tools.
General calibration information is
included in the section Calibration
information on page 247.

Continues on next page

3HAC022032-001 Revision: H 223
4 Repair
4.7.7. Refitting of motor, axis 5

Continued

Action Info
19.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 39.

© Copyright 2004-2010 ABB. All rights reserved.

224 3HAC022032-001 Revision: H

 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 in
the Product manual, reference information.

xx0300000164

A Motor unit, axis 4

B Motor unit, axis 5
© Copyright 2004-2010 ABB. All rights reserved.

C Motor unit, axis 6

D Attachment screws and washers, motor
E Connection box

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Motor unit, axis 6 3HAC10604-1 Elmo
(IRB 4400/45, /60, /L30, / Includes pinion.
S)
Motor unit, axis 6 3HAC10605-1 Elmo
(IRB 4400/L10) Includes pinion.
Motor unit, axis 6 3HAC021728-001 Yaskawa
(IRB 4400/45, /60, /L30, /S Includes pinion
and IRB 4450S)
Motor unit, axis 6 3HAC021962-001 Yaskawa
(IRB 4400/L10) Includes pinion

Continues on next page

3HAC022032-001 Revision: H 225
4 Repair
4.7.8. Refitting of motor, axis 6

Continued

Equipment, etc. Spare part no. Art. no. Note

O-ring 21522012-426
Gasket 3HAC3676-1 3 pcs
Between the motors and
the connection box.
Replace if damaged.
Standard toolkit 3HAC17594-1 The content is defined in
the section Standard
toolkit on page 275.
Measuring tool 3HAB1409-1
Power supply 24VDC, 1.5A
3 pcs, used to release the
brakes in the motors for
axes 4, 5 and 6.
Other tools and These procedures
procedures may be include references to the
required. See references tools required.
to these procedures in the
step-by-step instructions
below.
Circuit Diagram See the chapter Circuit
diagram.
Calibration Pendulum Art. no. is specified in
Instruction section Document
references on page 273in
part 2 of the Product
manual.

Refitting, motor axis 6

The procedure below details how to refit the axis 6 motor.

Action Info
1.
© Copyright 2004-2010 ABB. All rights reserved.

DANGER!
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.
2.

CAUTION!
Whenever parting/mating motor and gearbox, the
gears may be damaged if excessive force is used!
3.

NOTE!
The motor units from ELMO and YASKAWA are not
compatible!

Continues on next page

226 3HAC022032-001 Revision: H
 4 Repair
4.7.8. Refitting of motor, axis 6

Continued

Action Info
4. Check that the assembly surfaces are clean from
paint, lubricant etc.
Make sure that the motor and the gearbox are not
damaged or scratched.
5. Fit the o-ring to the new motor unit. Part no. is specified in Required
equipment on page 225.
6. Fit the measuring tool at the rear of the motor. Art. no. is specified in Required
equipment on page 225.
7. Release the brakes in the motors for axes 4, 5 and 6, Connect to connector R3.MP4/
by connecting the 24 VDC power supply. MP5/MP6
• +24V: pin 7
• 0V: pin 8.
8. Place the new motor unit in the gearbox.
Do not damage the pinion or the gear wheel!
9. Find the position of least play by turning the outgoing
shaft for axis 4 in intervals of 90°, one revolution in all,
to locate the area where the play for the axis 6 motor
is the smallest.
10. Turn the motor for axis 5 one full revolution at a time,
five revolutions in all. Find the least play for axis 6
within this range.
11. Turn the motor for axis 6 one full revolutipon at a time,
three turns in all. Find the least play for axis 6 within
this range.
12. Push the motor in a radial direction so that the play is
minimal within one motor revolution without the gear
"chewing".
13. Refit the motor with its attachment screws and Shown in the figure Location of
washers, motor. motor on page 225.
4 pcs, M6 x 25. Tightening
torque: 15 Nm.
14. Refill with oil, if drained. Detailed in section
© Copyright 2004-2010 ABB. All rights reserved.

• Oil change, gearbox

axis 5 and 6 (all robot
versions except IRB
4400/L10) on page 114.
• Oil change, gearbox
axis 5 and 6 (IRB 4400/
L10 only) on page 117.
15. Check the position of the three gaskets, located Part no. is specified in Required
between the motors and the connection box. Replace equipment on page 225.
them if damaged.
16. Refit the connection box. Shown in the figure Location of
Make sure the gaskets are seated properly! motor on page 225.
17. Reconnect all the connectors.
18. Refit the cover on the connection box.

Continues on next page

3HAC022032-001 Revision: H 227
4 Repair
4.7.8. Refitting of motor, axis 6

Continued

Action Info
19. Recalibrate the robot! Calibration is detailed in a
separate calibration manual
enclosed with the calibration
tools.
General calibration information
is included in the section
Calibration information on page
247.
20.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may
cause injury or damage! on page 39.

© Copyright 2004-2010 ABB. All rights reserved.

228 3HAC022032-001 Revision: H

 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. (The figure shows the IRB 4400.)
A more detailed view of the component and its position may be found in chapter Foldouts in
the Product manual, reference information.

xx0300000174

A Gearbox unit axes 1-3, spare part

© Copyright 2004-2010 ABB. All rights reserved.

B Bottom plate
C Attachment screws and washers, gearbox unit
D Sealing

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Gearbox unit, axes 1-3 3HAC 5948-1 Does not include motors
(IRB 4400/45, /60, /L10, / and lubricating oil.
L30)
Gearbox unit, axes 1-3 3HAC 5949-1 Does not include motors
(IRB 4400/S) and lubricating oil.
Gearbox unit, axes 1-3 3HAC 025482-001 Does not include motors
(IRB 4450S) and lubricating oil.
Sealing 3HAC 5479-2 Replace if damaged!

Continues on next page

3HAC022032-001 Revision: H 229
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 content is defined in
the section Standard
toolkit on page 275.
Lifting slings with hoisting Lifting capacity: 500 kg.
block
Other tools and These procedures
procedures may be include references to the
required. See references tools required.
to these procedures in the
step-by-step instructions
below.
Calibration Pendulum General calibration
instruction information is included in
the section Calibration
information on page 247.

Removal, gearbox unit

The procedure below details how to remove the gearbox unit, axis 1-2-3, including the
motors, from the robot.

Step Action Info/Illustration

1.

DANGER!
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.
2.

© Copyright 2004-2010 ABB. All rights reserved.

CAUTION!
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!
3.

CAUTION!
The base weighs 130 kg! All lifting
equipment used must be sized accord-
ingly!
4. Remove the cable harness and serial Detailed in sections Replacement of
measuring board. cable harness, axes 1-3 on page 127,
Removal of cable harness, axes 4-6 and
Replacement of serial measurement unit
on page 191.

Continues on next page

230 3HAC022032-001 Revision: H
 4 Repair
4.8.1. Replacement of gearbox unit, axes 1-2-3

Continued

Step Action Info/Illustration

5. Remove the tie rod. Detailed in section Replacement of tie rod
on page 175.
6. Remove the parallel arm. Detailed in section Replacement of
parallel arm / Replacement of bearing on
page 179.
7. Remove the complete arm system. Detailed in section Replacement of
complete arm system on page 139.
8. Unfasten the robot from the foundation.
9. Fit and secure straps (A) around the rear
part of the gearbox unit, as shown in the
figure to the right. Attach the straps to
lifting slings with a hoisting block.
Fit and secure hooks to the lifting lugs
(B).
Use the same crane for both attachment
points.

xx0300000172

This figure shows the IRB 4400.

xx0500002136

This figure shows the IRB 4450S.

© Copyright 2004-2010 ABB. All rights reserved.

10. Lift the gearbox unit together with the

base and use the hoisting block to tip the
complete assembly forward 90°.

Continues on next page

3HAC022032-001 Revision: H 231
4 Repair
4.8.1. Replacement of gearbox unit, axes 1-2-3

Continued

Step 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.
Note! The figure shows the IRB 4400
but the procedure for the IRB 4450S is
the same.

xx0300000173

• B: Approximately 200 mm (IRB

4400 all models)
• B: Approximately 230 mm (IRB
4450S)
12. Remove the bottom plate from the base. Shown in the figure Refitting, complete
arm system on page 142.
13. Move the lifting straps to the base and
unload its weight.
14. Remove the attachment screws and Shown in the figure Refitting, cabling
washers, gearbox unit. axes 1-3 on page 130.
15. Remove the base from the gearbox unit.

© Copyright 2004-2010 ABB. All rights reserved.

16. Remove the sealing from the gearbox
unit.

Continues on next page

232 3HAC022032-001 Revision: H
 4 Repair
4.8.1. Replacement of gearbox unit, axes 1-2-3

Continued

Refitting, gearbox unit

The procedure below details how to refit the gearbox unit, including motors, to the robot.

Step Action Info/Illustration

1.

DANGER!
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.
2.

CAUTION!
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!
3.

CAUTION!
The base weighs 130 kg! All lifting
equipment used must be sized accordingly!
4. Place the new gearbox unit 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 on the surface, including the weight
of the base that is to be refitted.
Note! The figure shows the IRB 4400 but
the procedure for the IRB 4450S is the
© Copyright 2004-2010 ABB. All rights reserved.

same.

xx0300000173

Part no. is specified in Required

equipment on page 229
B: Approximately 200mm (IRB 4400
all models)
B: Approximately 230 mm (IRB
4450S)

Continues on next page

3HAC022032-001 Revision: H 233
4 Repair
4.8.1. Replacement of gearbox unit, axes 1-2-3

Continued

Step Action Info/Illustration

5. Refit the sealing to the gearbox unit. Shown in figure Location of gearbox
Replace it if damaged. unit on page 229
Part no. is specified in Required
equipment on page 229
6. Raise the base and fit it to the gearbox unit.
Align the hole pattern of the base to the
gearboxes. Turn the gear if necessary by
the motor pinion, axis 1.
7. Refit the base with the attachment screws Shown in figure Location of gearbox
and washers, gearbox unit. unit on page 229
14 pcs, M16x80. 12.9 quality
UNBRAKO. Tightening torque: 260
Nm.
Reused screws may be used,
providing they are lubricated as
detailed in Screw joints in the Product
manual, reference information before
fitting.

8. Refit the bottom plate with its attachment Shown in the figure Location of
screws. gearbox unit on page 229
9. Strap the gearbox unit as in the removal See section Removal, gearbox unit on
instruction page 230
10. Lift the gearbox unit together with the base
and use the hoisting block to tip the
complete assembly backward by 90°, into
normal mounting position.
11. Refit the robot to the foundation.
12. Refit the complete arm system. Detailed in section Refitting, complete
arm system
13. Refit the parallel arm. Detailed in section Refitting, parallel
arm/bearing on page 181
14. Refit the tie rod. Detailed in section Refitting, tie rod on
© Copyright 2004-2010 ABB. All rights reserved.
page 177
15. Refit the cable harness and serial Detailed in sections Refitting, cabling
measuring board. axes 1-3 on page 130
16. Recalibrate the robot! Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in the section Calibration
information on page 247.
17.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER -
First test run may cause injury or damage!
on page 39.

234 3HAC022032-001 Revision: H

 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.

xx0300000191

A Cover
B Attachment screws, cover
C Screws, 3 pcs

Required equipment

Spare part
Equipment, etc. Art. no. Note
no.
Flange sealing 1234 0011-116 Loctite 574
Standard toolkit 3HAC 17594-1 The content is defined in the
section Standard toolkit on
page 275.
Other tools and These procedures include
© Copyright 2004-2010 ABB. All rights reserved.

procedures may be references to the tools

required. See references required.
to these procedures in the
step-by-step instructions
below.

Continues on next page

3HAC022032-001 Revision: H 235
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.

Step Action Info/Illustration

1.

DANGER!
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.
2. Remove the motors for axes 4, 5 and 6. Detailed in section Removal of motor,
axes 4, 5 and 6 on page 216.
3. Remove the cover. Shown in the figure Illustration,
adjusting play on page 235.
4. Unlock the three screws. Shown in the figure Illustration,
adjusting play on page 235.
5. Rotate axis 4 to find the highest position of
the gear on the upper arm tubular.
6. Tighten the three screws again. 3 pcs, tightening torque: 69 Nm.
7. Apply flange sealing to the cover and refit it Art. no. is specified in Required
with its attachment screws and washers. equipment on page 235.
10 pcs: M8x40. Tightening torque: 24
Nm.

© Copyright 2004-2010 ABB. All rights reserved.

236 3HAC022032-001 Revision: H

 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.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 237

4 Repair
4.9.2. Repair routines

4.9.2. Repair routines

Overview
Follow the instruction in the Repair chapter, with the following additional measure.

Equipment Article number

Cable strap 21662055-3
Sikaflex 521FC 3HAC026759-001
Drill diameter 8.8 mm

Replacement of motor axes 1-3

The following procedure details how to replace motors axes 1-3.

Action Note
1. Apply Sikaflex 521FC on both
sides of the gasket between motor
and cable box before mounting
the cable box.

xx0600003111

• A: Sikaflex
• B: Gasket
2. Cut the projecting part of the
gasket with a knife.
3. Apply Sikaflex 521FC outside the © Copyright 2004-2010 ABB. All rights reserved.
gasket and the cover plate around
the motor.

xx0600003112

• A: Sikaflex

Continues on next page

238 3HAC022032-001 Revision: H
 4 Repair
4.9.2. Repair routines

Continued

Action Note
4. Apply Sikaflex 521FC underneath
the cover attachment screw
heads.

xx0600003113

• A: Sikaflex
© Copyright 2004-2010 ABB. All rights reserved.

Continues on next page

3HAC022032-001 Revision: H 239
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
1. Drill and tap holes in the cable boxes for the Cable box, motor unit axes 1-3
air fittings before mounting a new cable
harness.
Drill diameter: 8.8mm
Thread: 1/8" pipe thread

xx0600003114

• A: Air connection on motor cable

box axis 1.
• B: Air connection on motor cable
box axis 2 and 3 (not used earth
connection.

Cable box, motor unit axes 4-6

© Copyright 2004-2010 ABB. All rights reserved.

xx0600003115

• A: Air connection on motor cable

box axis 4-6

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240 3HAC022032-001 Revision: H
 4 Repair
4.9.2. Repair routines

Continued

Replacement of balancing device

The following procedure details how to replace the balancing device.

Action Note
1. Before mounting the balancing device in the
robot, apply Mercasol 3106 on both side of
the ear and both side of the washers.

xx0600003123

• A: Mercasol 3106
© Copyright 2004-2010 ABB. All rights reserved.

Replacement of air hose (Required equipment)

5
6

4 2

3
xx0600003342

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3HAC022032-001 Revision: H 241
4 Repair
4.9.2. Repair routines

Continued

Equipment Article number

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
Air hose 3HAC026526-001 According to table:
Pneumatic house Length
7500 mm
Straight plug connector 3HAC026516-001/ 1 Pos 4 in figure above
Straight fitting 3HAC026507-001/ 4 Pos 5 in figure above
Adapter 3HAC027569-001/ 1 Pos 7 in figure above

xx0600003343

Pneumatic Article number

Note © Copyright 2004-2010 ABB. All rights reserved.
house 3HAC026526-001
A 140 mm From the Bulkhead plug in the front plate to the T-
plug connector for the SMB box, se step 1 and 2
in Replacement of air hose on page 243
B 270 mm From the T-plug connector to the stright plug
connector in the SMB box.
C 3050 mm From the T-plug connector through the base and
up to the Y-plug connector at the motors of axis
4,5,6, se step 3-5 in Replacement of air hose on
page 243.
D 40 mm From the Y-plug connector at axis 4,5,6 motors to
the straight fitting in the motor cover axis 4,5,6.
E 1750 mm From the Y-plug connector at axis 4,5,6 motors to
the the Y-plug connector at for the motors of axis
3, se step 6 in Replacement of air hose on page
243.

Continues on next page

242 3HAC022032-001 Revision: H
 4 Repair
4.9.2. Repair routines

Continued

Pneumatic Article number

Note
house 3HAC026526-001
F 425 mm From the Y-plug connector at axis 3 motors to the
straight fitting in the motor cover axis 3.
G 80 mm From the Y-plug connector at axis 3 to the Y-plug
connector for the balancing cylinder.
H 460 mm From the Y-plug connector for the balancing
cylinder to the elbow fitting in the bak of the
balancing cylinder, se step 7 in Replacement of air
hose on page 243.
K 220 mm From the Y-plug connector for the balancing
cylinder to the T-plug connector for axis 1 and axis
2.
L 140 mm From the T-plug connector to the straight fitting in
the motor cover axis 1.
M 365 mm From the T-plug connector to the straight fitting in
the motor cover axis 2.
N 150 mm To the Bulkhead plug in the front plate.

Replacement of air hose

The following procedure details how to replace the air hose.

Action Note
1. -The air is let in via the cover of the rear side
of the foot where a bulkhead plug for Ø6mm
plastic hose is mounted.
-A Plastic hose is drawn from the bulkhead
plug to a T-plug connector and led to the
SMB-compartment.
© Copyright 2004-2010 ABB. All rights reserved.

xx0600003116

2. The hose is drawn through a drilled hole in

the rubber sealing and firmly tightened with a
straight fitting.

xx0600003117

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3HAC022032-001 Revision: H 243
4 Repair
4.9.2. Repair routines

Continued

Action Note
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. A
bulkhead is mounted in the hole to prevent
wear on the hose.
-The hose must be able to run free in the
bulkhead.

xx0600003119

5. The hose continue through the lower arm

and is connected to a Y-plug connector at the
upper arm housing.

© Copyright 2004-2010 ABB. All rights reserved.

xx0600003119

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244 3HAC022032-001 Revision: H
 4 Repair
4.9.2. Repair routines

Continued

Action Note
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. From the Y-plug connector for the balancing

cylinder to the elbow plug in the back of the
balancing cylinder.
© Copyright 2004-2010 ABB. All rights reserved.

xx0600003344

3HAC022032-001 Revision: H 245

4 Repair
4.9.2. Repair routines

© Copyright 2004-2010 ABB. All rights reserved.

246 3HAC022032-001 Revision: H

 5 Calibration information
5.1. Introduction

5 Calibration information
5.1. Introduction

General
This chapter includes general information about different calibration methods and also details
procedures that do not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to the documentation
enclosed with the calibration tools.

When to calibrate
The system must be calibrated if any of the following situations occur.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied by ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in the section Calibration methods on page 248, and further
detailed in separate calibration manuals.
If the robot has Absolute Accuracy calibration, it is also recommended but not always
necessary to calibrate for new absolute accuracy.
The resolver values will change when parts affecting the calibration position are replaced on
the robot, for example motors, or parts of the transmission.

The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See Updating
revolution counters on page 254. This will occur when:
• the battery is discharged
• a resolver error occurs
• the signal between a resolver and measurement board is interrupted
• a robot axis is moved with the control system disconnected
© Copyright 2004-2010 ABB. All rights reserved.

The revolution counters must also be updated after the robot and controller are connected at
the first installation.

The robot is rebuilt

If the robot is rebuilt, for example after a crash or when the robot is changed for other
reachability, it needs to be recalibrated for new resolver values.
If the robot has Absolute Accuracy calibration, it needs to be calibrated for new absolute
accuracy.

3HAC022032-001 Revision: H 247

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 by ABB.

Types of calibration

Type of
Description Calibration method
calibration
Standard The calibrated robot is positioned at home Calibration Pendulum
calibration position, that is the axes’ positions (angles) are (standard method)
set to 0º. or
Standard calibration data is found on the SMB Levelmeter calibration
(serial measurement board) in the robot. (alternative method)
For robots with RobotWare 5.04 or older the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute Accuracy Based on standard calibration, and besides CalibWare
calibration positioning the robot at home position, the
(optional) Absolute Accuracy calibration also
compensates for:
• mechanical tolerances in the robot
structure.
• deflection due to load.
Absolute Accuracy calibration focuses on
positioning accuracy in the Cartesian
coordinate system for the robot.
Absolute Accuracy calibration data is found on
the SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older the
Absolute Accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at © Copyright 2004-2010 ABB. All rights reserved.
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absacc
compensation parameters.
A robot calibrated with Absolute Accuracy has
a sticker next to the identification plate of the
robot.
To regain 100% Absolute Accuracy perfor-
mance, the robot must be recalibrated for
absolute accuracy!

xx0400001197

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248 3HAC022032-001 Revision: H
 5 Calibration information
5.2. Calibration methods

Continued

Calibration methods
Each calibration method is detailed in a separate manual. Below is a brief description of the
methods available.

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.
Two different routines are available for the Calibration Pendulum method:
• Calibration Pendulum II
• Reference Calibration
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including the operating manual for Calibration Pendulum, which describes the method and
the different routines further.

Levelmeter Calibration - alternative method

Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots
because of the less accurate values obtained during calibration. The method uses the same
principles as Calibration Pendulum but does not have as good of mechanical tolerances to the
toolkit parts as the standard method with Calibration Pendulum.
This method may, after calibration, require modifications in the robot program and is
therefore not recommended.
The calibration equipment for Levelmeter Calibration is ordered as separate parts for each
robot and the operating manual for Levelmeter Calibration is enclosed with the Levelmeter
2000.

CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy
calibration is used as a TCP calibration. The CalibWare tool guides through the calibration
process and calculates new compensation parameters. This is further detailed in the
© Copyright 2004-2010 ABB. All rights reserved.

application manual Absolute Accuracy Calibware Field 5.0.

If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy
calibration is required in order to establish full performance. For most cases after motor and
transmission replacements that do not include taking apart the robot structure, standard
calibration is sufficient. Standard calibration also supports wrist exchange.

References
Article numbers for the calibration tools are listed in the section Special tools on page 276.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including Operating manual - Calibration Pendulum, which describes the method and the
routines further.

3HAC022032-001 Revision: H 249

5 Calibration information
5.3. Calibration scale and correct axis position

5.3. Calibration scale and correct axis position

Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.

© Copyright 2004-2010 ABB. All rights reserved.

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250 3HAC022032-001 Revision: H
 5 Calibration information
5.3. Calibration scale and correct axis position

Continued

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.
© Copyright 2004-2010 ABB. All rights reserved.

xx0500002239

A Punch axis 2, 3HAB 1521-1

B Punch axis 3, 3HAB 1522-1
C Punch axis 4, 3HAB 1523-1 (there are two different versions of the marks, as
shown in the figure)
D Punch axis 5, 3HAB 1524-1
E Axes 5 and 6, IRB 4400/L10

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5 Calibration information
5.3. Calibration scale and correct axis position

Continued

Calibration scales, IRB 4400

The illustration shows the calibration scale positions on IRB 4400.
The calibration marks for axes 2, 3, 4 and 5 are marked using punch mark tools.

© Copyright 2004-2010 ABB. All rights reserved.

xx0300000209

A Punch, axis 2, 3HAB 1521-1

B Punch, axis 3, 3HAB 1522-1
C Punch, axis 4, 3HAB 1523-1 (there are two different versions of the marks, as shown
in the figure)
D Punch, axis 5, 3HAB 1524-1
E Axes 5 and 6, IRB 4400/L10

252 3HAC022032-001 Revision: H

 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 and so on.
Positive directions are shown in the graphic below.
This is normally handled by the robot calibration software.

Calibration movement directions, 6 axes

Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis
robots, except the positive direction of axis 3 for IRB 6400R which is in the opposite
direction!
© Copyright 2004-2010 ABB. All rights reserved.

xx0200000089

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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, that is 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, that is, manually
running the robot to the calibration position.

Action Note
1. Select axis-by-axis motion mode.
2. Jog the robot to place the calibration marks Shown in the section Calibration scale and
within the tolerance zone. correct axis position on page 250.
IRB 140, 1400, 2400, 4400, 6600ID/
6650ID, 6640ID: Axes 5 and 6 must be
positioned together!
3. When all axes are positioned, store the Described in the section
revolution counter settings. Step 2 - Storing the revolution counter
setting with the TPU on page 254
(RobotWare 4.0).
Step 2 - Storing the revolution counter
setting with the FlexPendant on page 256
(RobotWare 5.0).

Step 2 - Storing the revolution counter setting with the TPU

This section details the second step when updating the revolution counter; storing the
revolution counter setting with the TPU (RobotWare 4.0).

Action Note
1. Press the button "Miscellaneous" then ENTER to select the service
window.
© Copyright 2004-2010 ABB. All rights reserved.

xx0100000194

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254 3HAC022032-001 Revision: H
 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. Select the desired unit and choose Rev Counter Update from the
Calib menu.
The Revolution Counter Update window appears.

xx0100000202
© Copyright 2004-2010 ABB. All rights reserved.

4. Select the desired axis and press Incl to include it (it will be marked
with an x) or press All to select all axes.
5. Press OK when all axes that are to be updated are marked with an x.
CANCEL returns to the Calibration window.
6. Press OK again to confirm and start the update.
CANCEL returns to the Revolution Counter Update window.
7. At this point, it is recommended that the revolution counter values are Not required.
saved to a diskette.
8.

CAUTION!
If a revolution counter is incorrectly updated, it will cause incorrect robot
positioning, which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
How to perform the check is detailed in section Checking the calibration
position on page 258.

Continues on next page

3HAC022032-001 Revision: H 255
5 Calibration information
5.5. Updating revolution counters

Continued

Step 2 - Storing the revolution counter setting with the FlexPendant

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.
2. Tap the mechanical unit in question.
A screen is displayed, tap Rev. Counters.

en0400000771

3. Tap Update Revolution Counters....

© Copyright 2004-2010 ABB. All rights reserved.

A dialog box is displayed warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
4. Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
5. A dialog box is displayed warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from the
list of axes.

Continues on next page

256 3HAC022032-001 Revision: H
 5 Calibration information
5.5. Updating revolution counters

Continued

Action
6.

CAUTION!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See the section Checking the calibration position on page 258.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 257

5 Calibration information
5.6. Checking the calibration position

5.6. Checking the calibration position

General
Check the calibration position before beginning any programming of the robot system. This
may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the FlexPendant.

Using a MoveAbsJ instruction on the TPU, S4Cplus

This section describes how to create a program that runs all the robot axes to their zero
position

Action Note
1. Create a new program.
2. Use MoveAbsJ.
3. Create the following program: MoveAbsJ
[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,
9E9]]\NoEOffs, v1000, z50, Tool0
4. Run the program in manual mode.
5. Check that the calibration marks for the axes align The calibration marks are shown in
correctly. If they do not, update the revolution the section Calibration scale and
counters. correct axis position on page 250.
How to update the revolution
counters is detailed in the section
Updating revolution counters on
page 254

Using a MoveAbsJ instruction on the FlexPendant, IRC5

Use this procedure to create a program that runs all the robot axes to their zero position.

Action Note
1. On ABB menu tap Program Editor. © Copyright 2004-2010 ABB. All rights reserved.
2. Create a new program.
3. Use MoveAbsJ in the Motion&Proc menu.
4. Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]\
NoEOffs, v1000, z50, Tool0
5. Run the program in manual mode.
6. Check that the calibration marks for the axes align The calibration marks are shown in
correctly. If they do not, update the revolution the section Calibration scale and
counters! correct axis position on page 250.
How to update the revolution
counters is detailed in section
Updating revolution counters on
page 254.

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258 3HAC022032-001 Revision: H
 5 Calibration information
5.6. Checking the calibration position

Continued

Using the Jogging window on the TPU, S4Cplus

This section describes how to jog the robot to all axes zero position.

Action Illustration/Note
1. Open the Jogging window.

xx0100000195

2. Choose running axes-by-axes.

xx0100000196

3. Manually run the robot axes to a position where the

axis position value read on the TPU, is equal to zero.
4. Check that the calibration marks for the axes align The calibration marks are
correctly. If they do not, update the revolution counters! shown in the section
Calibration scale and correct
axis position on page 250.
Detailed in the section
Updating revolution counters
on page 254.

Using the Jogging window on the FlexPendant

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 select group of axes to jog.
3. Tap to select the axis to jog, axis 1, 2, or 3.
4. Manually run the robots axes to a position where the
axis position value read on the FlexPendant, is equal
© Copyright 2004-2010 ABB. All rights reserved.

to zero.
5. Check that the calibration marks for the axes align The calibration marks are
correctly. If they do not, update the revolution counters! shown in the section
Calibration scale and correct
axis position on page 250.
How to update the counters is
detailed in section Updating
revolution counters on page
254.

3HAC022032-001 Revision: H 259

5 Calibration information
5.7. Additional calibration instruction, IRB4400

5.7. Additional calibration instruction, IRB4400

Instruction
Before updating the revolution counters (coarse calibration) on IRB 4400, the stainless steel
metal ring on axis 4 need to be removed.

Illustration

C
B

xx0600003124

A Upper arm
B Stainless steel ring
C Hose clamp

© Copyright 2004-2010 ABB. All rights reserved.

260 3HAC022032-001 Revision: H

 6 Decommissioning
6.1. Environmental information

6 Decommissioning
6.1. Environmental information

Hazardous material
The table specifies some of the materials in the robot and their respective use throughout the
product.
Dispose of the components properly to prevent health or environmental hazards.

Material Example application

Batteries, NiCad or Lithium Serial measurement board
Copper Cables, motors
Cast iron/nodular iron Base, lower arm, upper arm
Steel Gears, screws, base-frame, and so on.
Neodymium Brakes, motors
Plastic/rubber (PVC) Cables, connectors, drive belts, and so on.
Oil, grease Gearboxes
Aluminium Covers, sync. brackets

Oil and grease

Where possible, arrange for the oil and grease to be recycled. Dispose of via an authorized
person/contractor in accordance with local regulations. Do not dispose of oil and grease near
lakes, ponds, ditches, down drains or onto soil. Incineration must be carried out under
controlled conditions in accordance with local regulations.
Also note that:
• Spills may form a film on water surfaces causing damage to organisms. Oxygen
transfer could also be impaired.
• Spillage may penetrate the soil causing ground water contamination.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 261

6 Decommissioning
6.2. Decommissioning of balancing device

6.2. Decommissioning of balancing device

General
There is much energy stored in the balancing device. Therefore a special procedure is
required to dismantle it. The coil springs inside the balancing device exert a potentially lethal
force unless dismantled properly.
The device must be dismantled by a decommissioning company.

Required equipment

Equipment Art. no. Note

Standard toolkit - The content is defined in the section
Standard toolkit on page 275.
Cutting torch For opening housing and cutting coils
Other tools and procedures may be These procedures include references
required. See references to these to the tools required.
procedures in the step-by-step
instructions below.

DANGER!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!

Action on field, decommissioning

The procedure below details the actions to perform on field, when the balancing device is to
be decommissioned.

Action Note
1. Remove the balancing device from the robot.
2. Send the device to a decommissioning Make sure the decommissioning

© Copyright 2004-2010 ABB. All rights reserved.

company. company is well informed about the
stored energy built up by high tensioned
compression springs and that the device
contains some grease.
The following procedure contains useful
information about decommissioning.

Continues on next page

262 3HAC022032-001 Revision: H
 6 Decommissioning
6.2. Decommissioning of balancing device

Continued

Decommissioning at decommissioning company, balancing device

The instruction below details how to decommission the balancing device. Contact ABB
Robotics for further consultation.

Action Note
1.

DANGER!
There is stored energy built up by high
tensioned compression springs inside the
balancing device! The device also contains
some grease!
2. Place the device on a workbench or
similar. Make sure it is clamped in position
with a vice or similar.
3. Open a hole in the side of the housing as Use a cutting torch. The measurements
shown in the figure. shown below are maximum values!
4. Cut the coils of the three springs inside the Use a cutting torch.
housing as specified below:
• Outer spring: cut at least five coils!
• Middle spring: cut at least four coils!
• Inner spring: cut at least four coils!
5. Double-check the number of coils cut and
make sure all the tension in the springs is
removed.
© Copyright 2004-2010 ABB. All rights reserved.

3HAC022032-001 Revision: H 263

6 Decommissioning
6.2. Decommissioning of balancing device

© Copyright 2004-2010 ABB. All rights reserved.

264 3HAC022032-001 Revision: H

 7 Reference information
7.1. Introduction

7 Reference information
7.1. Introduction

General
This chapter includes general information, complementing the more specific information in
the different procedures in the manual.
© Copyright 2004-2008 ABB. All rights reserved.

3HAC022032-001 Revision: H 265

7 Reference information
7.2. Applicable safety standards

7.2. Applicable safety standards

Standards, EN ISO
The manipulator system is designed in accordance with the requirements of:

Standard Description
EN ISO 12100 -1 Safety of machinery - Basic concepts, general principles for
design - Part 1: Basic terminology, methodology
EN ISO 12100 -2 Safety of machinery - Basic concepts, general principles for
design - Part 2: Technical principles
EN ISO 13849-1 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-11 Robots for industrial environments - Safety requirements -Part 1
Robot
EN ISO 9787 Manipulating industrial robots, Coordinate systems and motion
nomenclatures
EN ISO 9283 Manipulating industrial robots, Performance criteria and related
test methods
EN ISO 14644-12 Classification of air cleanliness
EN ISO 13732-1 Ergonomics of the thermal environment - Part 1
EN IEC 61000-6-4 EMC, Generic emission
(option 129-1)
EN IEC 61000-6-2 EMC, Generic immunity
3
EN IEC 60974-1 Arc welding equipment - Part 1: Welding power sources
3
EN IEC 60974-10 Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part 1
General requirements
IEC 60529 Degrees of protection provided by enclosures (IP code)

1. There is a deviation from paragraph 6.2 in that only worst case stop distances and stop

© Copyright 2004-2008 ABB. All rights reserved.

times are documented.
2. Only robots with Protection Clean Room.
3. Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard Description
EN 614-1 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design
EN 953 Safety of machinery - General requirements for the design and
construction of fixed and movable guards

Continues on next page

266 3HAC022032-001 Revision: H
 7 Reference information
7.2. Applicable safety standards

Continued

Other standards

Standard Description
ANSI/RIA R15.06 Safety Requirements for Industrial Robots and Robot Systems
ANSI/UL 1740 Safety Standard for Robots and Robotic Equipment
(option 429-1)
CAN/CSA Z 434-03 Industrial Robots and Robot Systems - General Safety Require-
(option 429-1) ments
© Copyright 2004-2008 ABB. All rights reserved.

3HAC022032-001 Revision: H 267

7 Reference information
7.3. Unit conversion

7.3. Unit conversion

Converter table
Use the table below to convert units used in this manual.

Quantity Units
Length 1m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1L 0.264 US gal

© Copyright 2004-2008 ABB. All rights reserved.

268 3HAC022032-001 Revision: H

 7 Reference information
7.4. Screw joints

7.4. Screw joints

General
This section details how to tighten the various types of screw joints on the robot.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.

UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below) and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed. Using other types of screws will void any warranty and may
potentially cause serious damage or injury.

Gleitmo treated screws

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

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw
© Copyright 2004-2008 ABB. All rights reserved.

dimensions of M6 or smaller may be tightened without a torque wrenchif this is done

by trained and qualified personnel..

Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 11712016-618

Continues on next page

3HAC022032-001 Revision: H 269
7 Reference information
7.4. 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 descriptions. Any
special torque specified overrides the standard torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw in a slow,
flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.

Tightening torque (Nm)

Dimension
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0

The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.

Tightening torque Tightening torque Tightening torque

(Nm) (Nm) (Nm)
Dimension
Class 8.8, oil-lubri- Class 10.9, oil-lubri- Class 12.9, oil-lubri-
cated cated cated
© Copyright 2004-2008 ABB. All rights reserved.
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M24 725 960 1150

Continues on next page

270 3HAC022032-001 Revision: H
 7 Reference information
7.4. Screw joints

Continued

The table below specifies the recommended standard tightening torque for Molycote-
lubricated screws with Allen head screws.

Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8 28 35
M10 55 70
M12 96 120
M16 235 280
M20 550
M24 790 950

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

Tightening torque Tightening torque Tightening torque

Dimension
Nm - Nominal Nm - Min. Nm - Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90
© Copyright 2004-2008 ABB. All rights reserved.

3HAC022032-001 Revision: H 271

7 Reference information
7.5. Weight specifications

7.5. Weight specifications

Definition
In installation, repair and maintenance procedures, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are highlighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each
manipulator model.

Example
Below is an example of how a weight specification is presented, inside a procedure table:

Action Note

CAUTION!
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!

© Copyright 2004-2008 ABB. All rights reserved.

272 3HAC022032-001 Revision: H

 7 Reference information
7.6. Document references

7.6. Document references

General
This manual includes references to additional documentation necessary to perform certain
procedures. This section specifies the article numbers for the referenced documentation.

Product specification, robot

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

Document name Document ID

Product specification 3HAC9117-1 (M2000, M2004)

Product manuals, controller

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

Document name Document ID

Product manual, S4Cplus M2000 3HAC021333-001
Product manual, S4Cplus M2000A 3HAC022419-001
Product manual, IRC5 M2004 3HAC021313-001

Operating manual
The operating manual contains instructions for daily operation of robot systems. The table
below specifies the article numbers of the operating manuals for different robot systems.

Document name Document ID Note

User’s guide (S4Cplus) 3HAC7793-1 Contains instructions for daily operation
of S4Cplus based robot systems.
© Copyright 2004-2008 ABB. All rights reserved.

Operating manual - IRC5 with 3HAC16590-1

FlexPendant

Calibration manuals

Document name Document ID Note

Operating manual - Calibration 3HAC16578-1 Enclosed with the Calibration
Pendulum Pendulum tool set
Instructions for Levelmeter 3HAC022907-001 Enclosed with the Levelmeter 2000.
calibration (alternative method)
CalibWare Field 5.0 3HAC030421-001 Manual for Absolute Accuracy
Application Manual calibration

Continues on next page

3HAC022032-001 Revision: H 273
7 Reference information
7.6. Document references

Continued

Additional documentation

Document name Document ID Note

Operating manual - 3HAC025709-001 Details the Service
Service Information Information System of the
System, IRC5 robot systems M2004.
External axes 3HAC9299-1 S4Cplus based robot system.
Application manual - 3HAC021395-001 IRC5 based robot systems.
Additional axes and
stand alone controller

© Copyright 2004-2008 ABB. All rights reserved.

274 3HAC022032-001 Revision: H

 7 Reference information
7.7. Standard toolkit

7.7. 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.
This way, the tools required are the sum of the Standard toolkit and any tools listed in the
instruction.

Contents, standard toolkit

Qty Tool
1 Allen key 5-17 mm
1 Socket with ratchet
1 Box spanner set
1 Screwdriver
1 Torx socket no:20, 25, 30
1 Extension bar 100 mm
2 Puller bar
1 KM nut (KM10, KM17)
1 Lifting hoist
1 Cutting pliers
1 Torque wrench 10-470 Nm
© Copyright 2004-2008 ABB. All rights reserved.

3HAC022032-001 Revision: H 275

7 Reference information
7.8. Special tools

7.8. 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 the section Standard toolkit on page 275,
and of special tools, listed directly in the instructions and also gathered in this section.

Calibration equipment, Levelmeter (alternative method)

The table below specifies the calibration equipment required when calibrating the robot with
the alternative method, Levelmeter Calibration.

Description Art. no. Note

Angel bracket 68080011-LP
Calibration bracket 3HAC13908-9
Calibration tool ax1 3HAC13908-4
Levelmeter 2000 kit 6369901-347 Includes one sensor.
Measuring pin 3HAC13908-5
Sensor fixture 68080011-GM
Sensor plate 3HAC0392-1
Sync. adapter 3HAC13908-1
Turn disk fixture 3HAC68080011-GU

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.

© Copyright 2004-2008 ABB. All rights reserved.

276 3HAC022032-001 Revision: H

 7 Reference information
7.9. Lifting equipment and lifting instructions

7.9. 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.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
© Copyright 2004-2008 ABB. All rights reserved.

3HAC022032-001 Revision: H 277

7 Reference information
7.9. Lifting equipment and lifting instructions

© Copyright 2004-2008 ABB. All rights reserved.

278 3HAC022032-001 Revision: H

 8 Part list
8.1. Introduction

8 Part list
8.1. 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.
© Copyright 2004-2008 ABB. All rights reserved.

3HAC022032-001 Revision: H 279

8 Part list
8.2. Manipulator

8.2. 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

1 1 Foot 3HAC 5947-1
2 1 Gear box axes 1-3 3HAC 5948-1 /45, /60, L/10
2 1 Gear box axes 1-3 3HAC 5949-1 /FS, L/30
2 1 Gear box axes 1-3 3HAC 025482-001 IRB 4450S
3 26 Screw 3HAB 7700-88 M16x80 8.8, Gleitmo 610
4 14 Washer 3HAA 1001-186
5 1 Motor unit axis 1 (Elmo) 3HAC 5952-1 /45, /60, L/10, /L30
5 1 Motor unit axis 1 (Elmo) 3HAC 9841-1 /FS
5 1 Motor unit axis 1 (Yaskawa) 3HAC 021724-001 /45, /60, /L10 and 4450S
5 1 Motor unit axis 1 (Yaskawa) 3HAC 021725-001 /L30
5 1 Motor unit axis 1 (Yaskawa) 3HAC 021729-001 /FS
6 2 Motor unit axes 2 and 3 (Elmo) 3HAC 5954-1 /45, /60, /L10, /L30, /FS
6 2 Motor unit axes 2 and 3 3HAC 021725-001 /45, /60, /L10, /L30, /FS
(Yaskawa) and 4450S
7 3 O-ring 2152 0431-11 149x4
8 12 Spring washer 2154 2033-10 10.5x23x2.5
9 4 Screw 3HAB 3409-59 M10x70 12.9, Gleitmo
10 8 Screw 3HAB 3409-51 M10x30 12.9, Gleitmo
610
11 1 Lower arm 3HAC 5955-1 /45, /60, L/10, L/30
1 Lower arm 3HAC 5956-1 FS
11 1 Lower arm, complete 3HAC025476-001 IRB4450S
12 2 Spring washer 3HAB 3640-1

© Copyright 2004-2008 ABB. All rights reserved.

13 10 Screw 3HAB 3409-85 M16x55 12.9, Gleitmo
610
14 4 Cushion axis 2 3HAB 9237-1 /45, /60, L/10, L/30
15 2 Cushion axis 3 3HAB 3648-1
16 20 Screw 9ADA 629-56 M6x16 8
18 1 Parallel arm 45 kg 3HAB 8467-1 /45 and IRB 4450S
18 1 Parallel arm 60 kg 3HAB 8466-1 /60, L/30, L/10, FS
19 1 V-ring 3HAB 3732-11
20 1 Groove ball bearing 3HAB 3710-14 61830
21 1 Sealing ring 3HAB 3749-1
22 2 Washer 3HAC 7409-1
23 2 Sealing 3HAB 3701-25
24 2 Washer 3HAC 4160-1
25 1 Balancing unit 3HAC 15083-1 /45, /60, L/10, L/30
25 1 Balancing unit 3HAC 15083-2 /FS
25 1 Balancing unit 3HAC025477-001 IRB 4450S

Continues on next page

280 3HAC022032-001 Revision: H
 8 Part list
8.2. Manipulator

Continued

Item Qty Name Art.no Note

26 2 Shaft 3HAC 3970-1
27 1 Needle roller bearing 3HAB 3757-17
28 1 Securing plate 3HAC 4168-1
29 1 Stop pin 3HAB 3647-1
30 1 Cushion 3HAB 3741-1
31 1 Screw 9ADA 183-38 M8x30 8.8
32 1 Plain washer 9ADA 312-7 8.4x16x1.6
33 1 Stop screw 9ADA 205-73 M10x12
34 1 Sync. market axis 3 3HAB 3755-1
35 2 Washer 3HAB 3704-1
36 4 Screw 2121 2851-449 M8x16 8.8
37 3 Oil 1171 2016-604 3HAC 0575-1 6 litres, ISO VG 320EP./
45, /60, L/10, L/30,
37 4 Oil 1171 2016-604 3HAC 0575-1 Foundry 6 litres, ISO VG
320EP. FS
37 3 Oil 1171 2016-604 3HAC 0575-1 6.2 litres, ISO VG 320EP
IRB 4450S
38 Grease 3HAB 3537-1 200 g
39 Locking liquid 1269 0014-429 1 ml, Loctite 243
40 Sealing ring 3HAB 3701-26
41 2 V-ring 3HAB 3773-11
42 Grease 3HAC 2331-1 100 ml
43 4 Bearing sleeve 3HAC 4156-1 6.3 x 2.4
44 1 Cylindrical roller bearing 3HAC 4334-2
46 1 Screw 9ADA 183-48 M10x16 8.8
47 1 Plain washer 9ADA 312-8 10.5x20x2
48 1 Holder 3HAC 4162-1
49 2 Bushing 3HAC 3977-1
© Copyright 2004-2008 ABB. All rights reserved.

50 2 Sealing 3HAC 3297-1

51 1 Parallel bar 3HAC 1621-1
52 2 Spher. roller bearing 3HAA 2167-11
53 2 Sealing without dustlip 3HAC 3990-11
54 1 Upper arm without wrist and 3HAC17542-1 /45, /60 and IRB 4450S
motors
54 1 Upper arm without wrist and 3HAB 8281-1 F/45, F/60
motors
54 1 Upper arm without wrist and 3HAC 1670-1 L/30
motors
54 1 Upper arm without wrist and 3HAC 1629-3 L/10
motors
55 2 Sealing with dustlip 3HAC 7877-1
56 2 Tapper roller bearing 3HAA 2103-13
57 2 VK-cover 3HAA 2166-11 80x10
58 2 Lock nut 2126 2851-110 M50x1.5

Continues on next page

3HAC022032-001 Revision: H 281
8 Part list
8.2. Manipulator

Continued

Item Qty Name Art.no Note

59 2 Shaft end 3HAC 4744-1
60 1 Sync. market axis 2 3HAB 3754-1
61 4 Washer 3HAA 2356-13 6.4x22x1.5
63 1 Step protector 3HAC 3943-1
64 3 Air ventilation plug 3HAC 0127-1 /45, /60, L/10, L/30 and
IRB 4450S
64 2 Air ventilation plug 3HAC 0127-1 FS
65 2 V-ring 3HAB 3732-15
66 2 O-ring 3HAB 3772-23
67 1 Sealing 3HAC 5479-1
68 1 Sealing 3HAC 5479-2
69 1 Rubber protection 3HAC 7823-1 F/45 F/60 FL/30, FS
100 1 Cable unit axis 1-3 3HAC 5958-1 IRB 4400 all models
100 1 Cable unit axis 1-3 3HAC 025479-001 IRB 4450S
101 1 Cable unit axis 4-6 3HAC 8304-1 IRB 4400 all models
101 1 Cable unit axis 4-6 3HAC 025480-001 IRB 4450S
102 1 Bottom plate 3HAC 3692-1
103 1 Gasket 3HAC 3688-1
104 1 Cover 3HAC 8306-1 /45 /60 L/10 L/30 and
IRB 4450S
104 1 Cover 3HAC 8299-1 F/45 F/60 FL/30, FS
105 1 Gasket 3HAC 3547-1
106 1 Cable bushing 3HAC 3388-1
107 1 Bracket 3HAC 4116-1 IRB 4400
107 1 Bracket 3HAC 024049-001 IRB 4450S
108 2 Holder for cable guide 3HAB 3299-1
109 1 Cable guide 3HAB 3756-1
110 1 Spring 3HAB 3662-1
111 1 Cable guide upper arm 3HAB 3699-1 © Copyright 2004-2008 ABB. All rights reserved.
112 3 Cover 3HAC 2327-1
113 1 Cover punchb. 4400 3HAC 3585-1
114 1 Cover 3HAB 3666-1
116 23 Screw 2121 2416-329 M5x16 8.8
118 20 Nut with flange 9ADA 290-1 M5 fzb
119 30 Straps, outdoor 2166 2055-3 4.8x208
120 22 Bolt with flange 2121 2172-228 M5x12 8.8
121 1 Push button unit 3HAA 0001-ADX
122 4 Distance bolt 2125 2052-198 M5x15
123 1 Pushbutton guard 3HAC 2744-1
124 8 Screw 2121 2477-291 M4x12
125 1 Housing 64-p 5217 687-22 /45 /60 L/10 L/30 and
IRB 4450S
125 1 Protection cover 64-p 3HAC 7818-1 F/45 F/60 FL/30, FS

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282 3HAC022032-001 Revision: H
 8 Part list
8.2. Manipulator

Continued

Item Qty Name Art.no Note

126 1 Designition sign 3HAB 8431-1
127 36 Screw 9ADA 629-43 M5x10
128 1 Bracket 3HAC 024590-001 IRB 4450S
130 2 Screw 3HAC 4867-11 M20x90, UNBRAKO
12.9
132 2 Dust cap 3HAC 7561-3
133 1 Dust cap 3HAC 7561-4
135 6 Screw 9ADA 183-34 M8x12 8.8
137 34 Screw 9ADA 629-44 M5x12 8
138 15 Cable strap, indoor 2166 2054-1 2.5x101 mm
139 1 Coupling 3HAB 3333-20
140 Locking liquid 1269 0014-412 1 ml, Loctite 542
141 3 Protective hood 2522 2101-8 D=11.4 - 13
144 2 Spring pin 9ABA 142-62
147 3 Gasket 3HAB 3675-1
148 3 Gasket 3HAB 3676-1
150 Flange sealing 1234 0011-116 1 ml, Loctite 574
152 1 Gasket 3HAB 7097-1 /45 /60 L/10 L/30 and
IRB 4450S
153 9 Screw 9ADA 618-46 M5x20 8.8
154 1 Gasket 3HAB 9040-1 /45 /60 L/10 L/30 and
IRB 4450S
155 1 Housing 40-p 3HAB 6411-1 /45 /60 L/10 L/30 and
IRB 4450S
155 1 Protection cover 40-p 3HAC 7816-1 F/45 F/60 FL/30, FS
A 1 SIM-ring 2522 290-32 196.5x254x15/10 BAB 6
SL NLR
158 4 Cable starps, outdoor 2166 2055-6 Polyamide 6.6, black,
7.6x368
© Copyright 2004-2008 ABB. All rights reserved.

160 1 Counterweight 3HAC 7531-1 FS30

161 4 Hex socket head cap screw 3HAB 3409-50 Steel 12.9 M10x40,
Gleitmo 610

3HAC022032-001 Revision: H 283

8 Part list
8.3. Upper arm part, axes 4-6

8.3. 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

1 Upper arm without 3HAC 17542-1 Foundry, but also used for std
wrist and motors. version
1 12 Hex socket head 9ADA 183-40 M8x40 8.8-A2F
cap screw
2 10 Plain washer 9ADA 312-7 8.4x16x1.6 A2F
4 3 Hex socket head 3HAB 3409-57 M10x60 12.9. Gleitmo 610
cap screw
5 3 Spring washer 2154 2033-10 10.5x23x2.5 fzm
13 1 Stop axis 4 3HAB 3759-1
14 1 Damper 3HAB 3760-1
15 4 Screw 9ADA 183-35 M8x16 8.8
25 8 Screw 3HAB 3409-51 M10x30 12.9. Gleitmo 610
26 8 Plain washer 9ADA 312-8 10.5x20x2
/45, /60, F/45 and IRB 4450S
26 6 Plain washer 9ADA 312-7 8.4x16x1.6
F/60, L10, L/30, FL/30, FS8.
27 1 O-ring 2152 2012-541 199.3x5.7
/45, /60, F/45 and IRB4450S
27 1 O-ring 3HAB 3772-12 126x4
F/60, L/30, FL/30, FS, L/10
28 1 Wrist 3HAB 8271-1 F/45, F/60, FL/30, FS and IRB
4450S
28 1 Wrist 3HAB 9398-1 L/10
29 1 Gear, axis 6 3HAB3613-1

© Copyright 2004-2008 ABB. All rights reserved.

31 1 Flange sealing 1234 0011-116 1 ml, Loctite 574
33 4 Magnetic plug 2522 122-1 R1/4”
/45, /60, F/45, F/60, L/30 and IRB
4450S
33 2 Magnetic plug 2522 122-1 R1/4”
FL/30, FS
34 4 Sealing washer 2152 2031-6 13.7x20.6
/45, /60, F/45 and IRB 4450S
34 2 Sealing washer 2152 2031-6 13.7x20.6
F/60, L/30, FL/30, FSL/10
35 4 Lubricating oil 3HAC 0860-1 Axis 4: 3.4 litres Optimol
35 2 Lubricating oil 3HAC 0860-1 Axes 5 and 6: 3.4 litres Optimol.
/45, /60, F/45, F/60, L/30, FL/30, FS
and IRB 4450S. 0.8 litres Optimol,
L/10
48 3 O-ring 2152 2012-426 74.5x3

Continues on next page

284 3HAC022032-001 Revision: H
 8 Part list
8.3. Upper arm part, axes 4-6

Continued

Item Qty Name Art.no Note

49 1 Motor unit axis 4 3HAC 10603-1 /45, /60, /L10, /L30, FS
with pinion (Elmo)
49 1 Motor unit axis 5 3HAC 10603-1 /45, /60, /L30, /FS
with pinion (Elmo)
49 1 Motor unit axis 4 3HAC 021726-001 /45, /60, /L30, FS and IRB 4450S
with pinion
(Yaskawa)
49 1 Motor unit axis 4 3HAC 021962-001 /L10
with pinion
(Yaskawa)
49 1 Motor unit axis 5 3HAC 021726-001 /45, /60, /L30, /FS and IRB 4450S
with pinion
(Yaskawa)
50 1 Motor unit axis 5 3HAC 10605-1 /L10
with pinion (Elmo)
50 1 Motor unit axis 6 3HAC 10604-1 /45, /60, /L30, /FS
with pinion (Elmo)
50 1 Motor unit axis 6 3HAC 10605-1 /L10
with pinion (Elmo)
50 1 Motor unit axis 5 3HAC 021962-001 /L10
with pinion
(Yaskawa)
50 1 Motor unit axis 6 3HAC 021728-001 /45, /60, /L30, /FS and IRB 4450S
with pinion
(Yaskawa)
50 1 Motor unit axis 6 3HAC 021962-001 /L10
with pinion
(Yaskawa)
51 24 Screw 3HAB 3409-26 M6x25 12.9, Gleitmo 610
52 12 Conical spring 2154 2033-7 6.4x14x1.5
washer
52 1 Customer cable 3HAC 8820-1 Option 04y. See figure below!
© Copyright 2004-2008 ABB. All rights reserved.

extension, axis 4
56 1 Cover axis 4
57 6 Hex socket head 3HAB 3409-38 M8x30 12.9 Gleitmo 610, L/10
cap screw

Signal cabling, upper arm

xx0300000409

3HAC022032-001 Revision: H 285

8 Part list
8.4. Serial measurement unit

8.4. Serial measurement unit

Part list, serial measurement unit

See the Foldout 7 for location of parts.

Item Qty Name Art.no. Note

3 1 Battery pack, new 3HAC 16831-1 Lithium
3 1 Battery pack, old 4944 026-4 NiCd 7.2 V 4 Ah
4 4 Straps, outdoor 2166 2055-6 L=368 mm
5 1 Serial measurement board, 3HAC 17396-1 DSQC 562
new Includes battery 3HAC
16831-1
5 1 Serial measurement board, 3HAC 16014-1 Does not include battery!
new
7 1 Serial cable 3HAC7819-1
8 2 Straps, outdoor 2166 2055-3 L=208 mm
9 1 Label 2940 1413-1 38x19

© Copyright 2004-2008 ABB. All rights reserved.

286 3HAC022032-001 Revision: H

 8 Part list
8.5. Position switch, axis 1

8.5. Position switch, axis 1

Part list, position switch

See the Foldout 8 for location of parts.

Item Qty Name Art.no. Note

1 Pos. switch ax 1, 1 sw 3HAC 12042-1 Option 25-2 Standard,
complete set
1 Pos. switch ax 1, 1 sw 3HAC 12042-2 Option 25-2 Foundry,
complete set
1 Pos. switch ax 1, 2 sw 3HAC 12054-1 Option 25-4 Standard,
complete set
1 Pos. switch ax 1, 2 sw 3HAC 12054-2 Option 25-4 Foundry,
complete set
1 Pos. switch ax 1, 3 sw 3HAC 12071-1 Option 25-3 Standard,
complete set
1 Pos. switch ax 1, 3 sw 3HAC 12071-2 Option 25-3 Foundry,
complete set
1 Pos. switch cable 3HAC 7997-1 7m
1 Pos. switch cable 3HAC 7997-2 15 m
1 Pos. switch cable 3HAC 7997-3 22 m
1 Pos. switch cable 3HAC 7997-4 30 m
1 1 Position switch 1 3HAC 8039-1 ax1 pos.sw. (one) option
1 1 Position switch 1-2 3HAC 8040-1 ax1 pos.sw. (two) option
1 1 Position switch 1-3 3HAC 8041-1 ax1 pos.sw. (three) option
2 1 Segment Foundry 3HAC 6474-1 ax1 pos.sw. (one, two,
three)
3 3 Cam, blank 3HAC 4476-1 ax1 pos.sw. (one)
3 5 Cam, blank 3HAC 4476-1 ax1 pos.sw. (two)
3 7 Cam, blank 3HAC 4476-1 ax1 pos.sw. (three)
4 1 Bracket Foundry 3HAC 6558-1 ax1 pos.sw. (one, two,
© Copyright 2004-2008 ABB. All rights reserved.

three)
5 4 Distance bolt 2125 2052-216 2 1914-04 M6x55
protection (foundry)
5 3 Torx pan head roll. screw 9ADA 629-56 Steel 8-A2F, M4x20,
protection (foundry)
6 2 Hex socket head cap screw 9ADA 183-6 Steel 8.8-A2F. M4x20
ax1possw(one)
6 6 Hex socket head cap screw 9ADA 183-6 Steel 8.8-A2F. M4x20
ax1possw(two)
6 4 Hex socket head cap screw 9ADA 183-6 Steel 8.8-A2F. M4x20
ax1possw(three)
7 4 Shims-sheet 3HAB 7478-1 ax1possw(one)
7 8 Shims-sheet 3HAB 7478-1 ax1possw(two)
7 12 Shims-sheet 3HAB 7478-1 ax1possw(three)
9 6 Torx pan head roll. screw 9ADA 618-54 Steel 8.8-A2F, M6x10
ax1possw(one)

Continues on next page

3HAC022032-001 Revision: H 287
8 Part list
8.5. Position switch, axis 1

Continued

Item Qty Name Art.no. Note

9 12 Torx pan head roll. screw 9ADA 618-54 Steel 8.8-A2F,
M6x10ax1possw(two)
9 18 Torx pan head roll. screw 9ADA 618-54 Steel 8.8-A2F,
M6x10ax1possw(three)
10 1 Bracket position switch 3HAC 8057-1 Limit position switch
11 1 Hexagon nut 9ADA 267-5 Steel 8-A2F, M5
ax1possw(one)
11 1 Hexagon nut 9ADA 267-5 Steel 8-A2F,
M5ax1possw(two)
11 1 Hexagon nut 9ADA 267-5 Steel 8-A2F,
M5ax1possw(three)
12 1 Cable straps, outdoors 2166 2055-3 Polyamide 6.6 black
4.8x208, ax1possw (one,
two, three)
15 1 Label 2940 1413-1 B-619, 38x19 mm
ax1possw (one, two,
three) Text: R1.LS1. Text
height 3 mm
17 6 Hex socket counters, head 2121 2852-449 Steel 8.8 Fe/Zn 5c,
M8x16, ax1possw (one,
two, three)
19 1 Earth symbol 3HAB 5617-1 ax1possw(one, two,
three)
20 1 Assembly instruction 3HAC 7821-1
21 1 Plain washer 9ADA 312-5 Steel-A2F 5.3x10x1
ax1possw(one)
21 2 Plain washer 9ADA 312-5 Steel-A2F 5.3x10x1
ax1possw(two)
21 3 Plain washer 9ADA 312-5 Steel-A2F 5.3x10x1
ax1possw(three)
22 6 Plain washer 3HAB 8389-1 ax1possw(three)
23 2 Torx pan head roll. screw 9ADA 618-59 * Steel 8.8-A2F, M6x30,
ax1possw (one, two, © Copyright 2004-2008 ABB. All rights reserved.
three)
24 1 Box foundry switch 3HAC 6475-1 protection (foundry)
25 4 Torx pan head screw 9ADA 618-55 Steel 8.8-A2F, M6x12
protection (foundry)

* Excisting screws must be exchanged to this longer screws

288 3HAC022032-001 Revision: H

 9 Foldouts
9.1. Introduction

9 Foldouts
9.1. 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 280)
• Foldout 2: Manipulator (part list: Manipulator on page 280)
• Foldout 3: Manipulator (part list: Manipulator on page 280)
• Foldout 4: Manipulator (part list: Manipulator on page 280)
• Foldout 5: Manipulator (part list: Manipulator on page 280)
• Foldout 6.1: Upper arm part, axes 4-6 (part list: Upper arm part, axes 4-6 on page
284)
• Foldout 6.2: Upper arm part, axes 4-6 (part list: Upper arm part, axes 4-6 on page
284)
• Foldout 6.3: Upper arm part, axes 4-6 (part list: Upper arm part, axes 4-6 on page
284)
• Foldout 7: Serial measurement unit (part list: Serial measurement unit on page 286)
• Foldout 8: Position switch, axis 1 (part list: Position switch, axis 1 on page 287)
© Copyright 2004-2008 ABB. All rights reserved.

3HAC022032-001 Revision: H 289

9 Foldouts
9.1. Introduction

© Copyright 2004-2008 ABB. All rights reserved.

290 3HAC022032-001 Revision: H

 © Copyright 2004-2006 ABB. All rights reserved.

Foldout 1
 © Copyright 2004-2006 ABB. All rights reserved.

Foldout 2
 © Copyright 2004-2006 ABB. All rights reserved.

Foldout 3:1
 IRB 4450S

101
© Copyright 2004-2006 ABB. All rights reserved.

WARNING
ACHTUNG
ATTENTION

118

38
107 67 135 67 128 108 109

1.72 1.73

1.71

FO
UN
DR
PL Y
US
WARNING
ACHTUNG
ATTENTION

WARNING
ACHTUNG
ATTENTION

Foldout 3:2
 © Copyright 2004-2006 ABB. All rights reserved.

Foldout 4
 © Copyright 2004-2006 ABB. All rights reserved.

Foldout 5
 © Copyright 2004-2006 ABB. All rights reserved.

Foldout 6:1
 © Copyright 2004-2006 ABB. All rights reserved.

Foldout 6:2
 © Copyright 2004-2006 ABB. All rights reserved.

Foldout 6:3
 4 3

3hab 3365-1/x
Seriemätenhet
© Copyright 2004-2006 ABB. All rights reserved.

8 5 7 9
R1.G
R2.SMB
R1. SMB

Foldout 7
 © Copyright 2004-2006 ABB. All rights reserved.

Foldout 8
 10 Circuit diagram
10.1. About circuit diagrams

10 Circuit diagram
10.1. About circuit diagrams

Overview
The circuit diagrams are not included in this manual but delivered as separate documents on
the documentation DVD. See below for correct article numbers.

Controllers

Product Article numbers for circuit diagrams

IRC5 with Drive System 04 3HAC024480-004
IRC5 with Drive System 09 3HAC024480-005
IRC5 Panel Mounted Controller 3HAC026871-005
IRC5 Compact 3HAC031403-003

Manipulators

Product Article numbers for circuit diagrams

IRB 120 3HAC031408-003
IRB 140 3HAC6816-3
IRB 260 3HAC025611-001
IRB 360 3HAC028647-009
IRB 660 3HAC025691-001
IRB 1410 3HAC2800-3
IRB 1600 3HAC021351-003
IRB 2400 3HAC6670-3
IRB 2600 3HAC029570-007
IRB 4400/4450S 3HAC9821-1
3HAC9821-1
© Copyright 2004-2008 ABB. All rights reserved.

IRB 4600 3HAC029038-003

IRB 6400RF 3HAC8935-1
IRB 6600 type A 3HAC025744-001
IRB 6600 type B 3HAC025744-001
IRB 6620 3HAC025090-001
IRB 6620LX 3HAC025090-001
IRB 6640 3HAC025744-001
IRB 6650S 3HAC025744-001
IRB 6660 3HAC029940-001 (DressPack)
3HAC025744-001
IRB 7600 3HAC025744-001

3HAC022032-001 Revision: H 291

10 Circuit diagram
10.1. About circuit diagrams

© Copyright 2004-2008 ABB. All rights reserved.

292 3HAC022032-001 Revision: H

 Index

A I
Absolute Accuracy, calibration 249 installation
mechanical stop axis 1 75
B
mechanical stop axis 2 77
brakes position switch axis 3 80
testing function 26
L
C
labels
calibrating manipulator 34
roughly 254 Levelmeter calibration 249
calibration lifting equipment 272
Absolute Accuracy type 248
alternative method 249 M
Levelmeter calibration 249 manipulator
marks/scales 250 labels 34
rough 254 symbols 34
standard type 248 mechanical stop
when to calibrate 247 axis 1 75
calibration manual, article number 273 axis 2 77
calibration manuals 249 MoveAbsJ instruction
calibration position 254 FlexPendant 258
checking 258 TPU 258
jogging to, FlexPendant 259
N
jogging to, TPU 259
scales 250 negative directions, axes 253
calibration, Absolute Accuracy 249 O
CalibWare 248
carbon dioxide extinguisher 24 oil change
connection safety risks 42
external safety devices 14 operators manual, article number 273

D P
danger levels 32 paint surface damages 101
direction of axes 253 position switch
documentation axis 3 80
article numbers, other manuals 273 position, robot 250
calibration 273 positive directions, axes 253
controller 273 product manual, controller, article number 273
robot system 273 product specification, article number 273
protection standards 266
© Copyright 2004-2010 ABB. All rights reserved.

E
R
emergency stop
definition 30 repair
devices 31 painted surface 101
enabling device 28 responsibility and validity 14
ESD restricting
damage elimination 40 working range axis 1 75
sensitive equipment 40 working range axis 2 77
wrist strap connection point 40 working range axis 3 80
revolution counters
F storing on FlexPendant 256
fire extinguishing 24 storing on TPU 254
FlexPendant updating 254
jogging to calibration position 259 robot position 250
MoveAbsJ instruction 258
updating revolution counters 256
H
hold-to-run 28

3HAC022032-001 Revision: H 293

Index

S tools
safety calibration equipment, Levelmeter 276
brake testing 26 Calibration Pendulum equipment 276
emergency stop 30 for service 276
ESD 40 TPU
fence dimensions 23 jogging to calibration position 259
fire extinguishing 24 MoveAbsJ instruction 258
FlexPendant 28 updating revolution counters 254
introduction 13 U
manipulator system 14
updating revolution counters 254
moving manipulators 38
reduced speed function 27 V
release manipulator arm 25 validity and responsibility 14
service 14
signals 32 W
signals in manual 32 weight
symbols 32 gearbox unit 230, 233
symbols on manipulator 34 lower arm 172, 173
test run 39 working range
working range 29 restricting axis 1 75
wrist strap 40 restricting axis 2 77
safety equipment restricting axis 3 80
mechanical stop axis 1 75
mechanical stop axis 2 77
position switch axis 3 80
safety risk
electric parts 21
hot parts 17
hydraulic system 19
installation 15
oil change 42
operational disturbance 20
pneumatic system 19
tools 18
voltage 21
safety risks
service work 15
work pieces 18
safety signals
© Copyright 2004-2010 ABB. All rights reserved.
in manual 32
safety standards 266
scales on robot 250
signals
safety 32
special tools 276
standards
ANSI 267
CAN 267
EN 266
EN IEC 266
EN ISO 266
protection 266
safety 266
symbols
safety 32
sync marks 250
T
testing
brakes 26

294 3HAC022032-001 Revision: H

 3HAC 022032-001, Revision H, en

ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000