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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.

Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the robot and as a result of that affect
the active or passive safety operation. ABB is not liable for damages caused by
the use of non-original spare parts and special equipment. ABB is not liable for
damages or injuries caused by unauthorized modifications to the robot.

Connection of external safety devices

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

Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment
for the robot installation.

Allergenic material

See

Environmental information on page 277

for specification of allergenic materials

in the product, if any.

Product manual - IRB 4400

25

3HAC022032-001 Revision: Q

© Copyright 2004-2018 ABB. All rights reserved.

1 Safety

1.3.1 Safety risks during installation and service work on robots

Continued

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Summary of Contents for IRB 4400/60

Page 1: ...ROBOTICS Product manual IRB 4400 ...

Page 2: ...Trace back information Workspace R18 1 version a9 Checked in 2018 03 22 Skribenta version 5 2 025 ...

Page 3: ...Product manual IRB 4400 60 IRB 4400 L10 M2000 IRC5 Document ID 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved ...

Page 4: ...BB 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 Keep for future reference Additional copies of this manual may be obtained from AB...

Page 5: ...bols 39 1 4 1 Safety signals in the manual 41 1 4 2 Safety symbols on product labels 47 2 Installation and commissioning 47 2 1 Introduction 48 2 2 Installation and operational requirements for Foundry Prime robots 52 2 3 Unpacking 52 2 3 1 Pre installation procedure 56 2 3 2 Working range 59 2 4 On site installation 59 2 4 1 Lifting robot with roundslings 62 2 4 2 Manually releasing the brakes 65...

Page 6: ... SIS output logs 134 3 7 6 Exporting the SIS data 135 4 Repair 135 4 1 Introduction 136 4 2 General procedures 136 4 2 1 Mounting instructions for bearings 138 4 2 2 Mounting instructions for seals 140 4 2 3 Cut the paint or surface on the robot before replacing parts 142 4 2 4 Performing a leak down test 143 4 2 5 The brake release buttons may be jammed after service work 144 4 3 Complete robot 1...

Page 7: ...ronization marks and synchronization position for axes 268 5 4 Calibration movement directions for all axes 269 5 5 Updating revolution counters 274 5 6 Checking the synchronization position 276 5 7 Additional calibration instruction IRB 4400 277 6 Decommissioning 277 6 1 Environmental information 279 6 2 Decommissioning of balancing device 281 6 3 Scrapping of robot 283 7 Reference information 28...

Page 8: ...This page is intentionally left blank ...

Page 9: ...anical and electrical installation repair maintenance work Organization of chapters The manual is organized in the following chapters Contents Chapter Safety information Safety service Information about installation of the robot Installation and commissioning Information about maintenance work including mainten ance schedules Maintenance Information about repair work Repair Procedures that does no...

Page 10: ...050944 001 Operating manual Service Information System M2004 3HAC051016 001 Application manual Additional axes and stand alone controller i This manual contains all safety instructions from the product manuals for the manipulators and the controllers Revisions Description Revision First edition Replaces previous manuals Installation and Commissioning Manual Maintenance Manual Repair Manual part 1 ...

Page 11: ... about general illustrations added in section How to read the product manual on page 16 Some general tightening torques have been changed added see updated values in Screw joints on page 287 Added Safety risks during handling of batteries on page 36 All data about type of lubrication in gearboxes is moved from the manual to a separate lubrication manual see Type and amount of oil in gearboxes on p...

Page 12: ...ded Updated information regarding replacement of brake release board Added section to safety chapter The brake release buttons may be jammed after service work on page 143 Updated the description of dimensions pos A Mounting equipment on page 68 Updated information regarding disconnecting and reconnecting battery cable to serial measurement board P Published in release R18 1 The following updates ...

Page 13: ...safety standards unit conversions screw joints lists of tools Spare parts list with exploded views or references to separate spare parts lists 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 com...

Page 14: ...erence information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists Circuit diagrams or references to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Ap...

Page 15: ...The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRB 4400 15 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved Product documentation IRC5 Continued ...

Page 16: ...ompleted 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 Note Illustration Action Art no is...

Page 17: ...arried out by in experienced or non qualified personnel Foreign objects Force majeure Nation region specific regulations 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 robot is installed To be observed by the supplier of the complete system The integrator is respo...

Page 18: ...eed Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot 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 robot Safe handling Users shall not be exposed to hazards including sl...

Page 19: ...al parts through welding riveting or drilling of new holes into the castings The strength could be affected CAUTION Ensure that a gripper is prevented from dropping a work piece if such is used Product manual IRB 4400 19 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 1 Safety 1 1 1 Limitation of liability Continued ...

Page 20: ...view The protective stops and emergency stops are described in the product manual for the controller 20 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 21: ...uishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller Product manual IRB 4400 21 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 22: ... may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the robot does not increase the pressure on the trapped person further increasing any injury 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 22 Product m...

Page 23: ... arrest burn injuries or other severe injuries To avoid these personal injuries switch off the main power on the controller before proceeding work Note Switch off all main power switches in a MultiMove system Product manual IRB 4400 23 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 1 Safety 1 2 3 Make sure that the main power has been switched off ...

Page 24: ...afety lock Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller If the robot is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a robot standing directly on the floor Energy stored in the robot for the pur...

Page 25: ...fications to the robot Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment as we...

Page 26: ...y stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to...

Page 27: ...fore it is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If ...

Page 28: ...in USA or Canada Pay attention to the rotating axes of the robot Keep away from axes to not 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 robot or inside the cell Keep clear of moving parts so that limbs hands or fingers do not get trapped or crushed by the robot To prevent anyone else from taking control of the...

Page 29: ...manipulator switches to the MOTORS OFF state To ensure safe use of the teach pendant 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 robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to pr...

Page 30: ...lated 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 main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and...

Page 31: ...e 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 Product manual IRB 4400 31 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 32: ...e Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Product manual IRC5 Panel Mounted Controller Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of ...

Page 33: ... your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic Product manual IRB 4400 33 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 1 Safety 1 3 8 Ho...

Page 34: ...re must be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause a...

Page 35: ...as described below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the robot does not change position as the motors are switched off then the brake function is adequate Product manual IRB 4400 35 3HAC022032 001 Revision Q Cop...

Page 36: ...losion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Safe handling Use safety glasses when handling the batteries In the event of leakage wear rubber gloves and chemical apron In the event of fire use self contained breathing apparatus Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures ...

Page 37: ...ion Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic re...

Page 38: ... time to heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained vol...

Page 39: ...ccur if the instructions are not followed that can lead to serious injury pos sibly 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 WARNING xx0100000002 Warns for electrical hazards which could result in severe ...

Page 40: ...NOTE xx0100000004 Describes where to find additional information or how to do an operation in an easier way TIP xx0100000098 40 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 41: ...lish German and French Symbols on safety labels Description Symbol Warning xx0900000812 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 c...

Page 42: ... Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 42 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights re...

Page 43: ...ip over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 4400 43 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 44: ...1 1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 44 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 45: ...0001242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 4400 45 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 46: ...hat this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 46 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Contin...

Page 47: ...portant 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 page17 before performing any installation work Note If the IRB 4400 is connected to power always make sure that the robot is connected to protective...

Page 48: ...e gearboxes Pressurized components The motors the balancing device and the serial measurement board cavity must be pressurized on Foundry Prime robots during operation and shut down The overpressure can be dropped when atmospheric humidity has reached the same level as the surrounding environment At the installation of the Foundry Prime robot a pressure sensor and pressure relief valve not include...

Page 49: ... L min Air flow Pressurizing equipment ABB recommends a safety valve if not included set at 0 4 bar pressure sensor set at 0 2 0 3 bar or regulator set for maximum 0 3 bar to be attached on the pressure side of the air system Example of products Description Equipment Festo SDE1 series Pressure sensor Festo LRP series Pressure regulator Connect air hose to over pressure limiter unit Note ABB recomm...

Page 50: ...that protect the wrist from direct or indirect high pressure water jet Note Make sure that the special Foundry Prime painting of the robot is not broken during testing installation or repair work Use the touch up kit available for Foundry Prime article number 3HAC035355 001 to repair any damages in the paint Continues on next page 50 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004...

Page 51: ...environment Will avoid that humid air is trapped into gearboxes or other cavities due to raised vacuum when cooling down Will give the robot a chance to dry as most rust preventive components in washing detergents have a decaying effect i e the rust preventive effect is reduced after a time Please refer to the Product Specification of the washing detergent in question for decaying effect Washing d...

Page 52: ...he weight of the robot as specified in Weight robot on page 52 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 54 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 55 7 Before taking the robot to its installation site make sure that the site ...

Page 53: ...e shows the various forces and torques working on the robot during different kinds of operation 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 WARNING The robot installation is restricted to the mounting options given in following load table s Floor mounted Max load emergency stop Endurance lo...

Page 54: ...erpreted as the frequency of the robot mass inertia robot assumed stiff when a foundation translational torsional elasticity is added i e the stiffness of the pedestal where the robot is mounted The minimum resonance frequency should not be interpreted as the resonance frequency of the building floor etc For example if the equivalent mass of the floor is very high it will not affect robot movement...

Page 55: ...ction classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP54 Manipulator protection type Standard IP67 steam washable Manipulator protection type Foundry Prime Product manual IRB 4400 55 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Pre ins...

Page 56: ...fault working range for axis 6 can be extended by changing parameter values in the software Option 610 1 Independent axis can be used for resetting the revolution counter after the axis has been rotated no need for rewinding the axis IRB 4400 60 880 140 300 Pos 1 Pos 0 Pos 5 Pos 6 Pos 2 Pos 4 370 200 390 530 732 1955 1223 290 680 1720 2140 890 150 Pos 3 232 xx1100000592 Continues on next page 56 P...

Page 57: ... 1500 85 300 Pos 1 Pos 0 Pos 5 Pos 6 Pos 2 Pos 4 300 200 390 530 1070 2547 1477 680 1720 890 150 Pos 3 148 2450 905 xx1300002627 Positions at wrist center mm and angle degrees Angle degrees Axis 3 Angle degrees Axis 2 Position mm Z Position mm X Position no see figure above 0 0 1720 1700 0 Continues on next page Product manual IRB 4400 57 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All right...

Page 58: ... no see figure above 30 0 2450 1424 1 65 0 274 970 2 60 95 135 2401 3 24 95 786 500 4 40 70 1864 588 5 65 70 1265 845 6 58 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 3 2 Working range Continued ...

Page 59: ...gs CAUTION The IRB 4400 robot weighs 1300 kg All lifting accessories used must be sized 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 Continues on next page Product manual IRB 4400 59 3HAC02203...

Page 60: ... Information Action Detailed in section Manually releasing the brakes on page 62 Release the brakes manually to make it possible to alter the positions of the arms 1 Move the robot to the calibration position 2 Continues on next page 60 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 4 1 Lifting robot with roundslings...

Page 61: ...ox unit for axes 2 and 3 using lifting lugs 4 The roundsling and lifting lug dimensions must comply with the applicable stand ards specified in Required equipment on page 59 Lift the robot to its installation site 5 Make sure the slings do not rub against any sharp edges Product manual IRB 4400 61 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 2 Installation and commissionin...

Page 62: ... 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 This procedure details how to release the holding brakes with push buttons when the robot is connected to the controller Note Action xx0300000198 The internal brake release unit is located at the base of the robot 1 The brake rel...

Page 63: ...ixed up damage can be caused to the brake release unit and the intergrated quenching circuits xx0200000022 DANGER Incorrect connections can cause all brakes to be released simultaneously 1 Connect to connector R1 MP 0V pin B14 or B15 24V pin B16 The brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered accord ing to the numbers of the axes Release...

Page 64: ... the brake cable the brake will be released imme diately when the power is switched on This may cause some unexpected robot movements 1 See chapter Circuit diagram on page297 Axes 1 2 and 3 Pos 2 24 V Pos 5 0 V xx1400001984 Connect an external 24 VDC power supply to the motor according to the figures Note Be careful not to interchange the 24V and 0V pins If they are mixed up damage can be caused t...

Page 65: ...no Securing parts fact 3 pcs M20 Securing screws oiled 3 pcs Thickness 3 mm Washers Outer diameter 36 mm Inner diameter 21 mm 2 pcs 21510024 169 Guide sleeves Added to the rear bolt holes to allow the same robot to be re mounted without program adjustments Oiled screws 350 400 Nm Tightening torque xx0300000251 Level surface requirements Continues on next page Product manual IRB 4400 65 3HAC022032 ...

Page 66: ... plate to the foundation Info Illustration Action WARNING When the robot is put down before attach ment to the floor is done the risk of tipping is big if not properly secured 1 CAUTION The IRB 4400 robot weighs 1300 kg All lifting accessories used must be sized accordingly 2 Detailed in section Lifting robot with roundslings on page 59 Lift the robot 3 Move the robot to the vicinity of the instal...

Page 67: ...ring screws and washers in the base attachment holes 7 Attachment holes shown in the figure Hole configuration and dimensions on page 66 When bolting a mounting plate or frame to a concrete floor follow the general instructions for expansion shell bolts 8 The screw joint must be able to withstand the stress loads defined in section Loads on foundation robot on page 53 Product manual IRB 4400 67 3H...

Page 68: ... D D 29 5 15 29 5 25 50 144 340 300 54 20º 390 150 300 150 B B A A D D A C Max 15 kg 250 175 B B View H H B 106 200 110 A A E xx1300000001 Description Pos M8 x2 Used if option 218 6 is chosen depth of thread 9 mm A M8 x7 Depth of thread 14 mm B 571 mm C Continues on next page 68 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 2 Installation and commiss...

Page 69: ... 25 110 Max 2 kg 300 M5 2x D 240 22 78 43 A A 195 D 100 Max 35 kg C C 15º 120º 3x C C C xx1300002625 Description Pos M6 x2 Depth of thread 15 mm A M8 x3 Depth of thread 14 mm B M8 x3 R 92 mm depth of thread 16 mm If option 34 1 is chosen these holes are occu pied C Continues on next page Product manual IRB 4400 69 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 2 Installation...

Page 70: ...D 31 5 0 039 0 H8 A A A D 6 0 012 0 H7 Ø0 05 B M6 6x R 25 30º 6 0 º 5 x A A xx1300002626 For fastening of gripper tool flange to Robot tool flange every one of the screw holes for 6 screws quality class 12 9 shall be used Min 10 mm used thread length 70 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 4 4 1 Mounting eq...

Page 71: ...oad diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software User s guide S4Cplus BaseWare OS 4 0 Operating manual IRC5 with FlexPendant Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot For more information see product specification ...

Page 72: ...nical 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 72 Product manual IR...

Page 73: ... pcs lug included in 3HAB3833 1 9ADA183 71 Attachment screw M12x60 4 pcs lug included in 3HAB3833 1 9ADA312 9 Washer 13x24x2 5 Content is defined in section Standard tools on page 291 3HAC17594 1 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Continues ...

Page 74: ...the procedure Mounting instructions are also supplied with the kit Note Action See the figure Additional stops on page 74 for guidance Determine the position of the stop lugs and mark the hole positions on the base 1 Drill Ø10 2 mm to a maximum depth of 45 mm and tap with M12 thread Min thread depth 35 mm 2 Continues on next page 74 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 ...

Page 75: ... washers according to the figure Additional stops on page 74 3 M12x60 tightening torque 82 Nm oil lubrication Product manual IRB 4400 75 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Mechanically restricting the working range of axis 1 Continued ...

Page 76: ...Note Art no Spare part no Equipment etc Includes spacers dampers attachment screws and nuts 3HAC4225 1 Mechanical stop axis 2 3HAB9185 1 Spacer damper 3HAC3962 1 Spacer Content is defined in section Contents standard toolkit on page 291 3HAC17594 1 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedu...

Page 77: ...e lower arm A View B of the lower arm B Cut of the mech stop attachment C Spacer D Attachment screw spacer nut E Damper F Attachment screw damper nut G Continues on next page Product manual IRB 4400 77 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 5 3 Mechanically restricting the working range of axis 2 Continued ...

Page 78: ...orking range on page 78 Determine the working range restriction 1 Shown in the figure Additional stops on page 77 Fit both the spacers to either side of the gearbox unit with the attachment screws and nuts spacer 2 Art no is specified in Required equip ment on page 76 Attachment screw 1 pc spacer M16x70 Tightening torque 156 Nm Shown in the figure Additional stops on page 77 Fit the dampers to bot...

Page 79: ...w xx0300000262 Sealing with dust lip 3HAB 3701 14 A Stud 2122 2012 867 B All screws are locked with locking liquid C Tap 3HAB 3798 1 D Hexagon nut 9ADA 267 7 E Disc 3HAB 3799 1 F Screw 9ADA 618 44 G Cam 3HAB 3800 1 H Bracket 3HAB 8400 1 I Limit switch complete 3HAB 8312 1 J Screw 9ADA 629 50 K Attachment screw 9ADA 183 35 L Retaining ring 9ABA 135 18 reducing coupling 2686 015 3 washer 2152 398 3 ...

Page 80: ...ical stop to axis 3 Mounting instructions are also supplied with the kit Info Illustration Action xx0300000263 Remove the covers A from axis 3 1 Specified in Required equipment on page 80 All screws are locked with locking liquid when fitted 2 Fit the electrical stop according to the figure Electrical stop on page 79 3 The system parameters that must be changed Upper joint bound and Lower joint bo...

Page 81: ... in chapter Exploded views in Product manual spare parts IRB 4400 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 Exploded views in Product manual spare parts IRB 4400 xx0300000176 Mechanical stop axis 4 A Damper axis 4 B Attachment screws mechanical stop C Contin...

Page 82: ... all electric power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot work ing area 1 Shown in the figure Location of mechan ical stop axis 4 on page 81 Loosen the attachment screws mech stop and remove the mechanical stop axis 4 2 Slowly rotate axis 4 until the damper is visible through the hole 3 Remove the damper...

Page 83: ...s the most stable position Do not change the robot position before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position 0 xx0300000245 WARNING The robot is likely to be mechanically unstable if not secured to the foundation Product manual IRB 4400 83 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All ...

Page 84: ...R1 4 is located on the rear part of the upper arm and at the base Max 8 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 Connection sets To connect power and signal conductors to the robot base upper arm connectors the following parts are recommended Content Art no Connector Connection set so...

Page 85: ...area of 0 13 0 25 mm2 reduction hose bottled shaped reduction hose angled 3HAC12327 1 R2 CS R3 CS R2 CS R3 CS pins for cable area of 0 13 0 25 mm2 reduction hose bottled shaped reduction hose angled 3HAC12326 1 R2 CP R3 CP R2 CP R3 CP Product manual IRB 4400 85 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 6 1 Customer connection on robot ...

Page 86: ... base cable between robot and controller not supplied Customer Contact on Upper arm R2 Customer Ter minal Controller Signal name RI CP CS A1 R2 CP A XT6 1 CPA RI CP CS B1 R2 CP B XT6 2 CPB RI CP CS C1 R2 CP C XT6 3 CPC RI CP CS D1 R2 CP D XT6 4 CPD RI CP CS A2 R2 CP E XT6 5 CPE RI CP CS B2 R2 CP F XT6 6 CPF RI CP CSP Earth R2 CP G Earth Continues on next page 86 Product manual IRB 4400 3HAC022032 ...

Page 87: ...D5 R2 CS C XT5 3 CSC R1 CS CP A6 R2 CS D XT5 4 CSD R1 CS CP B6 R2 CS E XT5 5 CSE R1 CS CP C6 R2 CS F XT5 6 CSF R1 CS CP D6 R2 CS G XT5 7 CSG R1 CS CP A7 R2 CS H XT5 8 CSH R1 CS CP B7 R2 CS J XT5 9 CSJ R1 CS CP C7 R2 CS K XT5 10 CSK R1 CS CP D7 R2 CS L XT5 11 CSL R1 CS CP A8 R2 CS M XT5 12 CSM R1 CS CP B8 R2 CS N XT5 13 CSN R1 CS CP C8 R2 CS P XT5 14 CSP R1 CS CP D8 R2 CS R XT5 15 CSR R1 CS CP A9 R...

Page 88: ...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 100 Humidity 9 0 Washing detergent with pH Washing detergent must contain rust inhibitor and be approved by ABB 60 C used in a typical waterjet clean ing application at suitable speed Cleaning bath temperature Air specification for pressurizing of robot...

Page 89: ...mpressed air hose to air con nector on robot base see illustration 1 Do this when the controller cables are connected Protect the screws on the Harting connectors on the robot base from corrosion with Mer casol 2 See Air specification for pressurizing of robot on page 88 for correct pressure Pressurize the robot 3 See Inspection of air hoses Foundry Prime on page 106 Inspect the air system 4 Prote...

Page 90: ...ounting 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 must be protected Note Illustration Action A B xx0600003109 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 1 A screw holes and screws B unpainted surfa...

Page 91: ...robot in a water jet cleaning cell perform a inspection of the pressure in motors and SMB cavity 3 Product manual IRB 4400 91 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 2 Installation and commissioning 2 7 1 Installation of IRB 4400 in a water jet application Continued ...

Page 92: ...nsation in gearboxes it is required 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 92 Product manual IRB 4...

Page 93: ...regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 ...

Page 94: ...This page is intentionally left blank ...

Page 95: ... sections and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work 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 17 before performing any service work Note If ...

Page 96: ...lubrication Conditional for example water content in gearbox control decide replacement intervals Preventive measures every 6 months secure the uptime of the robot Inspection of oil level in gearboxes Surface treatment Cable harness Balancing device Activity to lubricate gearboxes cavities and gears Run each axis on high speed at least one occasion per hour This activity will lubricate the gearbox...

Page 97: ...ing means more frequent maintenance activities SIS specified by the robot s SIS Service Information System A typical value is given for a typical work cycle but the value will differ depending on how hard each part is run The SIS used in M2000 and M2000A is further described in the section Service Information System M2000 on page 127 The SIS used in M2004 is further described in the Operating manu...

Page 98: ...e gearbox axis 4 on page 118 12 000 hrs iv Oil gearbox axis 4 Change Oil change gearbox axis 5 and 6 all robot versions on page 121 12 000 hrs iv Oil gearbox axes 5 and 6 Change i The battery low alert 38213 Battery charge low is displayed when the battery needs to be replaced The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is ...

Page 99: ...lacing the SMB battery on page 109 Battery low alert vi Battery pack meas urement system with 2 pole battery con tact e g DSQC633A Replacement i Parts that need to be changed according to the maintenance schedule are not covered by warranty ii Must be replaced if bent iii Damage to painted surfaces must be repaired as soon as possible to avoid corrosion iv The gearboxes are lubricated for life whi...

Page 100: ...rning sign Heat 3 pcs B Warning sign Balancing cylinder C Rating label D ABB logotype 2 pcs E ABB logotype 2 pcs F Protection class logotype G Warning sign Symbol of flash 5 pcs H UL UR label J Calibration label 4 pcs K Instruction plate Lifting of robot L Designation sign M Continues on next page 100 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 3 M...

Page 101: ... the robot Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot work ing area 1 See the figure in Location of information labels on page 100 Check all labels 2 Replace any missing or damaged labels 3 Product manual IRB 4400 101 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 4 1 Inspecting infor...

Page 102: ...page 291 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit...

Page 103: ...DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot work ing area 3 Check whether the signal lamp is broken If so replace 4 Check the cable connections 5 24V Measure the voltage in connectors motor axis 3 6 Check the cabling If a fault is detected re place 7 Seal and paint the joints that have been opened Also repair possible damages of the sp...

Page 104: ... 291 Standard toolkit These procedures include ref erences to the tools required Other tools and procedures may be required See references to these procedures in the step by step in structions below 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 Continues on next page 10...

Page 105: ...or dam aged in any other way 2 Removal refitting of the mechanical stop is detailed in section Fitting mechanical stop axis 1 on page 74 Note If the mechanical stop pin has been deformed or damaged it must be replaced by a new one 3 Also check that the stop pin is properly attached 4 Product manual IRB 4400 105 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 4...

Page 106: ...rect value is shown on the pressure gauge 1 0 2 0 3 bar A B C xx0600003341 A Air Connection B Pressure gauge C Cut off valve It should take at least 5 seconds for the pressure to reach 0 bar Close the cut off valve 2 The time is 5 seconds If the answer is YES Localize the leakage by following the procedures below If the answer is NO The system is OK Remove the leak testing equipment 3 Pressurize b...

Page 107: ... When the leak is localized correct the leak 6 Product manual IRB 4400 107 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 4 4 Inspection of air hoses Foundry Prime Continued ...

Page 108: ...Note Article number Equipment Mercasol Recommended drying time is 24h 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit Inspection and repair of surface treatment Use this procedure to inspect the surface treatment on Foundry Prime robots Information Action Inspect all painted surfaces for damages 1 Repair damages ...

Page 109: ... production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions Location of battery pack The battery pack is fit to the serial measurement unit located inside the base To access the unit and battery pack the rear cover plate shown in the figure below must be removed xx0300000106 Rear cover plate A Required equipment Note There are two variants...

Page 110: ... in the section The unit is sensitive to ESD on page 32 Set the robot to the MOTORS OFF operating mode 2 This way the robot does not need to be calibrated after the battery change Shown in the figure Location of battery pack on page 109 Remove the rear cover plate from the base CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result i...

Page 111: ...after for example 6 months 4 If the oil level is decreased then replace the gearbox Oil spills discolors painted surfaces Oil spills on painted surfaces of the robot can result in discoloration Note After all repair and maintenance work involving oil always wipe the robot clean from all surplus oil Special cleaning considerations This section specifies some special considerations when cleaning the...

Page 112: ...th water and steam on page 112 Cleaning with water and steam Instructions for rinsing with water ABB robots with protection types Standard Foundry Plus Wash or Foundry Prime can be cleaned by rinsing with water water cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle ...

Page 113: ...inal specification it can become very corrosive Approved cleaners and detergents All cleaners and detergents must be approved by ABB before use Contact ABB Robotics Sales Support to get the latest released list of approved cleaners and detergents Temperature of cleaning bath Maximum temperature 60ºC Ambient temperature must not be higher than 45 C Note Make sure that the special Foundry Prime pain...

Page 114: ...e or changing activities of lubrication always contact the local ABB Service organization for more information For ABB personnel Always check ABB Library for the latest revision of the manual Technical reference manual Lubrication in gearboxes in order to always get the latest information of updates about lubrication in gearboxes A new revision will be published on ABB Library immediately after up...

Page 115: ... on the opposite side xx0300000331 Oil plug filling A 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 xx0300000220 Upper oil plug filling A Lower oil plug draining B Continues on next page Product manual IRB 4400 115 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 6...

Page 116: ...e procedures in the step by step instruc tions below Inspection oil level axis 2 3 The procedure below details how to inspect the oil level of the gearbox unit axes 2 3 Note Illustration Action Shown in the figure Location of oil plugs axes 2 and 3 on page 115 Remove the oil plug filling 1 The oil must cover at least half of the lower arm bearing Measure the oil level from the oil plug hole Requir...

Page 117: ...gs axis 4 on page 115 Remove the upper oil plug filling 2 Required oil level 4 mm to the edge of the oil plug hole 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 114 Fill with lubricating oil if necessary 4 Refit the oil plug 5 Inspection oil level axis 5 and 6 all robot versions The procedure below details how to inspect the oil level of wr...

Page 118: ...nts standard toolkit on page 291 3HAC17594 1 Standard toolkit The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below CAUTION Always cut the paint with a knife and grind the pain...

Page 119: ...g and drain the oil into an oil collecting vessel 2 Capacity of the oil collecting vessel is specified in Re quired equipment on page 118 Clean and refit the oil plug 3 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 speci...

Page 120: ... end upwards 1 Shown in the figure Location of oil plugs on page 118 Remove the upper oil plug filling 2 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 114 Fill the gearbox with lubricating oil 3 Correct oil level is specified in section Inspection of oil levels on page 115 Clean and refit the oil plug 4 120 Product manual IRB 4400 3HAC022032 ...

Page 121: ...is defined in section Contents standard toolkit on page 291 3HAC17594 1 Standard toolkit The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below CAUTION Always cut the paint with...

Page 122: ...y of oil collecting vessel is specified in Re quired equipment on page 121 Remove the other oil plug draining 4 Move axis 3 up 15 and let the oil run out for a couple of minutes 5 Shown in the figure Location of oil plugs on page 121 Turn axis 4 so that the oil plug filling is facing downwards 6 Remove the oil plug axis 5 to drain the oil 7 Move axis 3 down to 0 8 Move axis 4 backwards and forward...

Page 123: ...on Move the upper arm to a horizontal position and turn axis 4 to calibration position 1 Shown in the figure Location of oil plugs on page 121 Turn axis 4 so that the oil plug filling is facing up wards 2 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 114 Fill the wrist with lubricating oil through the oil plug hole filling Fill in intervals s...

Page 124: ...olume 800 ml Content is defined in section Standard tools on page 291 3HAC17594 1 Standard toolkit Capacity 1000 ml Oil collecting vessel These procedures include ref erences to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below CAUTION Always cut the paint with a knife and grind the paint edge when disassemblin...

Page 125: ...g in the wrist 2 Shown in the figure Location of oil plugs on page 124 Turn axis 4 to a position where the oil plug draining is faced downwards and drain the oil into an oil col lecting vessel Also remove the oil plug filling in order to use it as an air inlet 3 Capacity of vessel is spe cified in Required equipment on page 124 Turn axis 4 another 90 to allow the remaining oil to be drained 4 Clea...

Page 126: ...ut seals and gaskets prevent the manipulator from moving freely Note Illustration Action Step Move the upper arm to a horizontal position and turn axis 4 to the calibration position 1 Art no and amount are spe cified in Required equipment on page 124 Fill the wrist with lubricating oil through the oil plug hole filling 2 Correct oil level is specified in section Inspection oil level axis 5 and 6 a...

Page 127: ...ine what values are adequate and suit able for your application in your production environment 2 How to do this is detailed in Setting the SIS parameters on page 132 Enter these parameters in the system 3 Run the robot in normal operation 4 The TPU displays for resetting any SIS value are shown in Description of Service Information System SIS on page 128 Reset the counter if a repair is made or if...

Page 128: ...on percentage of the axis 6 gearbox service interval Counters are reset when maintenance has been performed The counter status is displayed after running the service routine for maintenance Status OK indicates that no service interval limit has been exceeded by that counter Calendar time This is a clock within the control system that keeps track of the service interval based on calendar time When ...

Page 129: ...133 The following information is available about the joint service status in the service routine Service status for axis x i e the automatically calculated time parameter has not been exceeded Joint x OK The service interval for the axis in question has been reached Joint x NOK No service time parameter calculation available Joint x N A Applies to axes 4 and 5 IRB 6600 and IRB 7600 The following i...

Page 130: ...ction made a message No data available is displayed when trying to display the data 130 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 7 2 Description of Service Information System SIS Continued ...

Page 131: ...rs selected as service interval E g by setting the value 2 the SIS will save this as the nominal time for activating the alarm not counting the percentage described below Calendar time warning A percentage of the Calendar time limit specified above E g by setting the value 90 the SIS will alert the operator after 90 of two years i e 657 days after a calendar time Reset was made the last time Gearb...

Page 132: ...m parameters using the TPU 1 Go to System paramet ers Manipulator types 2 2 Select 0 SIS parameters and press Enter 3 Select the required system The parameter list is dis played 4 Available parameters are described in section SIS system parameters on page 131 Select the required paramet ers by stepping up and down through the parameter list 5 132 Product manual IRB 4400 3HAC022032 001 Revision Q C...

Page 133: ...mit is detailed in section Setting the SIS parameters on page 132 Service Message Service is due X production hours since last service Operation time Proceed with the required service as detailed in chapter Repair on page135 or chapter Maintenance on page 95 depending on which type of service X number of operation hours remain until the manually set operation time limit expires Service Message X p...

Page 134: ...eration hours since the system was started Corresponds to the oper ating time counter on the control cabinet Operation time seconds sisTotRunT The number of operation hours since start last reset of the operation time counter Corres ponds to the operating time counter on the control cabinet Operation time seconds sisRunT Estimated life of gearbox axis 1 Gearbox time hours sisL10h_1 Operation time ...

Page 135: ...perform a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 283 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sur...

Page 136: ...e exposed to any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing graduall...

Page 137: ...arted 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 following description 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 Product manual IRB 4400 ...

Page 138: ...s of the correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page138 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and...

Page 139: ...nly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically c...

Page 140: ...e robots re gardless of the original color of the robot 3HAC035355 001 Touch up paint Foundry Prime Foundry Prime 2 Foundry Prime 3 Grey 3HAC037052 001 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edg...

Page 141: ...035355 001 Use Touch up paint Foundry Prime grey to paint the joint Note Always read the instruction in the product data sheet in the paint repair kit for Foundry Prime 6 Apply Mercasol on all screw heads and set screws after tightening 7 Product manual IRB 4400 141 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 3 Cut the paint or surface on the robot before rep...

Page 142: ... must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no pressure l...

Page 143: ...e to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jam...

Page 144: ... position may be found in chapter Exploded views in Product manual spare parts IRB 4400 xx0300000111 Rear cover plate A 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 B Continues on next page 144 Product manual IRB 4400 3HAC022032 001 Revision Q ...

Page 145: ...le of axis 1 G Protection plate H Required equipment Note Art no Spare part no Equipment etc IRB 4400 all models See Product manual spare parts IRB 4400 Cable harness axes 1 3 Between the motor and the connection box axes 1 2 and 3 3HAC4432 1 Gasket Replace if damaged Content is defined in sec tion Standard tools on page 291 3HAC17594 1 Standard toolkit Continues on next page Product manual IRB 44...

Page 146: ...g the robot working area 1 Shown in the figure Location of cable harness axes 1 3 on page 144 Remove the rear cover plate 2 Removal detailed in section Removal serial measurement unit on page 208 Remove the serial measurement unit 3 Shown in the figure Location of cable harness axes 1 3 on page 144 Loosen the connectors R1 MP1 R2 FB1 3 R2 BU R2 BU1 3 Also loosen the earth connections 4 Cut all the...

Page 147: ...efit the connection boxes to the motors 1 2 3 Replace the gaskets if they are damaged 3 Shown in the figure Location of cable harness view X X on page 145 Reconnect the connectors in the motors 1 2 3 4 Shown in the figure Location of cable harness view X X on page 145 Refit the cable guide and the protection plate in the middle of axis 1 5 See chapter Exploded views in Product manual spare parts I...

Page 148: ...uded in section Calibra tion on page 263 DANGER Make sure all safety requirements are met when perform ing the first test run These are further detailed in the section First test run may cause injury or damage on page 27 14 148 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 1 Replacement of cable harness axes 1 3 Continued ...

Page 149: ...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 B 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 connections R2 CP R2 CS F Cable bracket inside the lower arm I Cable br...

Page 150: ...ent etc IRB 4400 all models See Product manu al spare parts IRB 4400 Cable harness axes 4 6 3 pcs 3HAB3676 1 Gasket Between the motor and the connection box Replace if damaged Content is defined in sec tion Standard tools on page 291 3HAC17594 1 Standard toolkit These procedures include references to the tools re quired Other tools and proced ures may be required See references to these pro cedure...

Page 151: ... Foundry Prime robots to the robot before entering the robot work ing area 1 Remove the cover ot the connection box for motors 4 5 6 2 Shown in the figure Location of cable harness axes 4 6 on page 149 Remove the rear cover plate 3 Detailed in section Removal serial measurement unit on page 208 Remove the serial measurement unit 4 Shown in the figure Location of cable harness axes 4 6 on page 149 ...

Page 152: ...ge 149 Loosen the cable bracket inside the lower arm and undo the two screws 11 Shown in the figure Location of cable harness axes 4 6 on page 149 Loosen the cable bracket at the upper arm 12 Shown in the figure Location of cable harness axes 4 6 on page 149 Loosen all the connectors to the motors at the upper arm and customer connections if any 13 Remove the connection box together with the cabli...

Page 153: ...1 Connector R3 FB4 A2 Axis 5 motor B Connector R3 MP5 B1 Connector R3 FB5 B2 Axis 6 motor C Connector R3 MP6 C1 Connector R3 FB6 C2 Protection plate D Cable strap indoor E cable strap outdoor F Continues on next page Product manual IRB 4400 153 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 2 Replacement of cable harness axes 4 6 Continued ...

Page 154: ...ge 153 Refit the protection plate in the connection box 5 Run the cabling through the lower arm 6 Shown in the figure Location of cable harness axes 4 6 on page 149 Refit the cable bracket at the upper arm 7 Shown in the figure Location of cable harness axes 4 6 on page 149 Refit the cable bracket inside the lower arm 8 Shown in the figure Location of cable harness view X X on page 150 Feed the ca...

Page 155: ...parate calibration manual enclosed with the calibration tools Recalibrate the robot 17 General calibration information is included in section Calibration on page 263 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the section First test run may cause injury or damage on page 27 18 Product manual IRB 4400 155 3HAC022032 001 Revision...

Page 156: ...tachment screws and friction washers lower arm C Parallel arm D V ring between lower arm and gearbox axis 3 E Required equipment Note Art no Spare part no Equipment etc 2 pcs 3HAB3773 11 V ring On both sides of the lower arm in the frame Used to grease sealings and bearings 3HAB3537 1 Grease Content is defined in section Standard tools on page 291 3HAC17594 1 Standard toolkit Continues on next pag...

Page 157: ...ure below details how to remove the complete arm system from the robot Info Illustration Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot work ing area 1 CAUTION The robot arm system weighs 245 kg All lifting accessories used must be sized accordingly 2 Detailed in section ...

Page 158: ...lacement of bearing on page 194 Remove the parallel arm 8 Shown in the figure Location of complete arm system on page 156 Remove the attachment screws and friction washers lower arm 9 Lift away the complete arm system Make sure the upper and lower arm are properly secured to each other during the lift 10 Refitting complete arm system The procedure below details how to refit the complete arm system...

Page 159: ...tion of complete arm system on page 156 Make sure both V rings are seated properly Grease the bearing seating of the parallel arm in the lower arm to prevent clicking during operation 6 Detailed in section Refitting parallel arm bearing on page 196 Refit the parallel arm 7 Detailed in section Refitting of balancing device on page 203 Refit the balancing device 8 Move the upper arm to a horizontal ...

Page 160: ...ncluded in section Calibration on page 263 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 27 13 160 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of complete arm system Continued ...

Page 161: ...ts position may be found in chapter Exploded views in Product manual spare parts IRB 4400 xx0300000129 Upper arm A Connectors of motors axes 4 5 and 6 B Connection box upper arm C Calibration plate axis 3 D VK cover E KM nut F Screw G Bearing H Sealing ring I Shaft end J Continues on next page Product manual IRB 4400 161 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repai...

Page 162: ... 3HAB1463 1 Mounting tool Contains two separate parts Used to evacuate air when re fitting VK cover if the cover has no grooves for venting 3HAC8704 1 De air tool These procedures include ref erences to the tools required Other tools and proced ures may be required See references to these proced ures in the step by step in structions below Art no is specified in section Calibration on page 263 Cal...

Page 163: ...onnection box upper arm from the motors 7 Shown in the figure Location of upper arm on page 161 Remove the calibration plate axis 3 8 Shown in the figure Location of upper arm on page 161 Remove the VK covers on both sides of the upper arm Be careful with the bearing beneath the cov er Make a hole in the outer edge of the cover and bend it away 9 Shown in the figure Location of upper arm on page 1...

Page 164: ... is specified in Required equip ment on page 162 Shown in the figure Location of upper arm on page 161 Insert both screws 6 2 pcs tightening torque 470 Nm Art no is specified in Required equip ment on page 162 xx0300000130 If the bearing is removed the inner ring of the bearing is fitted as follows Fit the holding on tool part A of the mounting tool on the right side of the upper arm seen from beh...

Page 165: ...d in section Replacement of com plete upper arm on page 161 Refit the tie rod 11 Shown in the figure Location of upper arm on page 161 Refit the calibration plate axis 3 12 Shown in the figure Location of upper arm on page 161 Refit the connection box 13 Shown in the figure Location of upper arm on page 161 Reconnect the connectors to motors axes 4 5 and 6 14 Calibration is detailed in a separate ...

Page 166: ...r Exploded views in Product manual spare parts IRB 4400 xx0300000150 Wrist unit A O ring B Sealing surface between wrist unit and upper arm tube C Attachment screws and washers D Required equipment Note Art no Spare part no Equipment etc 3HAB8271 1 Wrist unit IRB 4400 ABB Orange 3HAB9398 1 Wrist unit IRB 4400 L10 Graphite White 3HAC050646 001 Continues on next page 166 Product manual IRB 4400 3HAC...

Page 167: ...0 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 this ...

Page 168: ...ould be sent to ABB for service etc ABB recommends its customers carry out only the following servicing repair work on this unit Info Illustration Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot work ing area 1 CAUTION The robot wrist unit weighs 48 kg All lifting accessor...

Page 169: ... 6 all robot versions on page 121 Fill the wrist unit with oil 5 Calibration is detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the robot 6 General calibration information is included in section Calibration on page 263 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test ...

Page 170: ...uipment etc Foundry also used for Stand ard 3HAC17542 1 Upper arm without wrist and motors Color ABB Orange Foundry also used for Stand ard 3HAC050860 001 Color Graphite White Content is defined in section Standard tools on page 291 3HAC17594 1 Standard toolkit These procedures include ref erences to the tools required Other tools and procedures may be required See refer ences to these procedures ...

Page 171: ...s 4 on page 170 Remove the wrist unit 2 Detailed in section Removal of motor axes 4 5 and 6 on page 233 Remove the motors for axes 4 5 and 6 3 Detailed in section Replacement of arm house unit axis 4 on page 170 Remove the arm house unit 4 Part no is specified in Required equip ment on page 170 Fit the new arm house unit 5 Detailed in section Replacement of wrist unit on page 166 Refit the wrist u...

Page 172: ...forming the first test run These are further detailed in the section First test run may cause injury or damage on page 27 9 172 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 3 Replacement of arm house unit axis 4 Continued ...

Page 173: ...ical stop C Required equipment Note Art no Spare part no Equipment etc 3HAB8856 1 Mechanical stop axis 4 3HAB3760 1 Damper Loctite 574 12340011 116 Flange sealing Content is defined in sec tion Standard tools on page 291 3HAC17594 1 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step ...

Page 174: ... mechanical stop The procedure below details how to remove the axis 4 mechanical stop from the robot Info Illustration Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot working area 1 Shown in the figure Location of mechanical stop on page 173 Remove the mechanical stop by r...

Page 175: ... page 173 Fit the damper to the axis 4 2 Part no is specified in Re quired equipment on page 173 Art no is specified in Re quired equipment on page 173 Apply flange sealing to the stop 3 Shown in the figure Location of mechanical stop on page 173 Fit the mechanical stop to the axis 4 with its attach ment screws 4 Part no is specified in Re quired equipment on page 173 4 pcs M8x16 Tightening torque...

Page 176: ...axis 4 Content is defined in section Standard tools on page 291 3HAC17594 1 Standard toolkit These procedures include ref erences to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the r...

Page 177: ...holders from the tube shaft 3 Disconnect the connectors at the rear of the upper arm 4 Refitting signal cabling upper arm The procedure below details how to refit the signal cabling to the upper arm Note Illustration Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot working ...

Page 178: ...y rotate axis 4 clockwise to its stop posi tion 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 6 Complete the rotation Note Do not tighten the rear cable holder leave it open 7 Continues on next page 178 Pro...

Page 179: ... with no excessive pulling 9 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 10 Tighten the holders by hand Do not use tools 11 Reconnect the connectors at the rear end of the upper arm 12 Connect the air hose 13 Secure the cables and air hose together with cable ...

Page 180: ...tions below Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit 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 Information Action DANGER Tu...

Page 181: ... differ ent robot versions as specified to the right 4 Values for robot version IRB 4400 A Measuring tool play B 100 mm C 140 mm F 200 N Values for robot version IRB 4400 L10 A Measuring tool play B 140 mm C 85 mm F 40 N Remove the load and set the dial indicator to zero 5 Continues on next page Product manual IRB 4400 181 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Rep...

Page 182: ...sion IRB 4400 L10 A Measuring tool play B 140 mm C 85 mm F 40 N The maximum play allowed at the given distance from the center of axis 5 is for robot version IRB 4400 0 20 mm IRB 4400 L10 0 08 mm Remove the load and measure the play by reading the dial indicator 7 182 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 6 Measuring the play axi...

Page 183: ... equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit 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 Information Action DANGER Turn off all electric po...

Page 184: ... tool play B 140 mm m 10 kg xx0300000189 Apply load F in one direction Note Different load and distances for the differ ent robot versions as specified to the right 4 Values for robot version IRB 4400 A Measuring tool play B 100 mm C 100 mm F 100 N Values for robot version IRB 4400 L10 A Measuring tool play B 100 mm C 150 mm F 40 N Remove the load and set the dial indicat or to zero 5 Continues on...

Page 185: ...ion IRB 4400 L10 A Measuring tool play B 100 mm C 150 mm F 40 N The maximum play allowed at the given distance B from the center of axis 6 is for robot version IRB 4400 0 15 mm IRB 4400 L10 0 2 mm Remove the load and measure the play by reading the dial indicator 7 Product manual IRB 4400 185 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 7 Measuring the play ax...

Page 186: ...ows the IRB 4400 A more detailed view of the component and its position may be found in chapter Exploded views in Product manual spare parts IRB 4400 xx0300000141 Lower arm A Continues on next page 186 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 5 1 Replacement of lower arm ...

Page 187: ...n the step by step instructions be low General calibration information is included in section Calibra tion on page 263 Calibration Pendulum In struction CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page140 Removal lower arm The procedure below details how to remove the lower arm from ...

Page 188: ...Refitting lower arm The procedure below deatails how to refit the lower arm to the robot Info Illustration Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot working area 1 CAUTION The robot lower arm weighs 65 kg All lifting accessories used must be sized accord ingly 2 Part...

Page 189: ...device 9 Detailed in section Refitting upper arm on page 164 Refit the upper arm 10 Detailed in section Refitting cabling axes 4 6 on page154 Refit the cabling 11 Calibration is detailed in a separate calibration manual enclosed with the calibration tools Recalibrate the robot 12 General calibration informa tion is included in section Calibration on page 263 DANGER Make sure all safety requirement...

Page 190: ...ews in Product manual spare parts IRB 4400 xx0300000117 Tie rod A Attachment screw B Washer C O ring D Sealing outside E Spherical roller bearing F Sealing inside G Required equipment Note Art no Spare part no Equipment etc Replace if damaged 3HAB3704 1 Washer Continues on next page 190 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 5 2 Rep...

Page 191: ...ocedures may be required See refer ences to these procedures in the step by step instruc tions below General calibration informa tion is included in section Calibration on page 263 Calibration Pendulum In struction CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page140 Removal tie rod T...

Page 192: ... robot working area 1 Part Art no is specified in Required equipment on page 190 If the bearings are to be replaced fit new spherical roller bearings and new sealings inside to the tie rod Use the press tool 2 Lift the tie rod to its mounting site Make sure the tie rod is refitted with the correct end up 3 Art no is specified in Re quired equipment on page190 Grease the shaft on the robot and refi...

Page 193: ... is included in section Calibration on page 263 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the section First test run may cause injury or damage on page 27 9 Product manual IRB 4400 193 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 5 2 Replacement of tie rod Continued ...

Page 194: ...nlarged view A more detailed view of the component and its position may be found in chapter Exploded views in Product manual spare parts IRB 4400 xx0300000128 Parallel arm A Attachment screw B Washer C V ring on parallel arm D Bearing E Sealing F Continues on next page 194 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 5 3 Replacement of pa...

Page 195: ...aint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page140 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 Info Illustration Action DANGER Turn off all electric power supply hydraulic pre...

Page 196: ... 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 Info Illustration Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot working area 1 CAUTION The parallel arm system weighs 118 kg All lifting acces...

Page 197: ...on before fitting Detailed in section Refitting tie rod on page 192 Move the upper arm to a horizontal pos ition with a crane if not already posi tioned horizontal and refit the tie rod 7 xx0300000127 Reposition the cabling and tighten the cable attachment screws 8 Calibration is detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the robot 9 General calibra...

Page 198: ...omponent and its position may be found in chapter Exploded views in Product manual spare parts IRB 4400 xx0300000100 Balancing device A Bracket B Attachment screws bracket M12x50 C Press out hole D Front screws E Fork F End part of shaft G Continues on next page 198 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 6 1 Replacement of balancing...

Page 199: ...ntents are defined in section Standard tools on page 291 3HAC17594 1 Standard toolkit M10x40H Securing front screws H threaded to the head Used to unload the balan cing device before removal Used to fit the cylindrical roller bearings and the seal ings into the brackets 3HAC5465 1 Press tool bearing These procedures include references to the tools re quired Other tools and proced ures may be requi...

Page 200: ...ic power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot working area 2 CAUTION The balancing device weighs 50 kg All lifting accessories used must be sized accordingly 3 xx0300000088 Move the manipulator to the calibration pos ition as shown in the figure to the right 4 A Approximately 2º Continues on next page 2...

Page 201: ...000095 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 6 Dimension specified in Required equip ment on page 199 Check that the piston is unloaded by moving it manually 7 Continues on next page Product manual IRB 4400 201 3HAC022032 001 Revision Q Copyright 2004 2018 ABB ...

Page 202: ...from the frame by pressing it out using a M10x30 screw in the press out hole 9 xx0300000099 Remove the balancing device by pushing it to the side Note The balancing device weighs 50 kg 10 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 11 Continues on next page 202 Product manual IRB 4400 3HAC022032 001 Revision...

Page 203: ...rackets if the balancing device is a new spare part the old bearings sealings are damaged 4 Part no is specified in Required equip ment on page 199 If the balancing device is a new spare part it must be unloaded as described in Removal balancing device on page200 Lift the balancing device to its mounting posi tion 5 Shown in the figure Location of balan cing device on page 198 Fit the balancing de...

Page 204: ...oring the balancing device check that the fork is in position the fork does not cover the lubrication holes of the shaft 10 xx0300000095 Restore the balancing device by removing the replacement front screws A and refitting the original protection front screws 11 2 pcs MC6S M10x12 8 8 fzb Shown in the figure above in Refitting of balancing device on page 203 Refit the fork to the shaft in the lower...

Page 205: ...evices shaft 1 Art no is specified in Re quired equipment on page199 Fit the outer ring of the bearing into both brackets with a press toll bearing 2 Part no is specified in Re quired equipment on page199 Fit the sealing ring with dust lip with the same but turned press tool bearing 3 Art no and amount specified in Required equipment on page 199 Lubricate the bearing and the sealing with grease 4 ...

Page 206: ... cover plate A Different versions serial measurement unit Note There are different variants of SMB units and batteries The variant with the 3 pole battery contact has longer lifetime for the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not replace the battery contact Continues on next page 206 Product manual IRB 4400 3HAC022032 00...

Page 207: ...andard tools on page 291 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below See chapter Circuit diagram on page 297 Circuit diagram CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on th...

Page 208: ...AUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 3 Cut all the straps 4 Unscrew the nuts that attaches the serial meas urement unit inside the base 5 Remove the serial measurement unit 6 The connectors are shown in the figure Different versions serial measurement unit on page 206 Remove the connectors from ...

Page 209: ...he serial measurement unit Make sure the lock on the battery cable connector R2 G snaps into place during refitting 3 The connectors are shown in the figure Different versions serial measurement unit on page 206 Refit the serial measurement unit inside the base using nuts 4 Strap the cables 5 Shown in the figure Location of serial measurement unit on page 206 Refit the rear cover plate on the base...

Page 210: ...e A Connectors on the brake release board The connectors X8 X9 and X10 are placed on the brake release board as shown in the figure below X9 X8 X10 xx1700000978 Required equipment Note Article num ber Spare part num ber Equipment etc DSQC1050 3HAC065019 001 Brake release unit with harness and bracket Content is defined in section Standard tools on page 291 3HAC17594 1 Standard toolkit Continues on...

Page 211: ...g area 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 32 2 Secure the robot by moving the lower arm to one of its end positions the upper arm to its end position 3 Shown in the figure Location of the brake release board on page 210 Remove the rear cover plate CAUTION Clean co...

Page 212: ...tachment screws Note Make sure that the guard plate is mounted when the screws for brake release unit are reassembled 3 Shown in the figure Connect ors on the brake release board on page 210 Refit the connectors X8 X9 and X10 to the brake re lease board Be careful not to damage the sockets or pins 4 Make sure the connector and its locking arms are snapped down properly Verify that the robot cablin...

Page 213: ...d in section Calibration on page 263 Recalibrate the robot 8 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the section First test run may cause injury or damage on page 27 9 Product manual IRB 4400 213 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 6 3 Replacement of the brake release board Conti...

Page 214: ... 3HAB3647 1 Mechanical stop axis 1 Content is defined in section Standard tools on page 291 3HAC17594 1 Standard toolkit These procedures include ref erences to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut t...

Page 215: ... Prime robots to the robot before entering the robot working area 1 Shown in the figure in Loca tion of mechanical stop pin on page 214 Remove the set screw 2 Shown in the figure in Loca tion of mechanical stop pin on page 214 Remove the old mechanical stop pin 3 Part no is specified in Re quired equipment on page 214 Refit the new mechanical stop with the set screw 4 M10x12 Product manual IRB 440...

Page 216: ...IRB 4400 xx0300000154 Motor axis 1 A Connection box with cover B Attachment screws and washers C Required equipment Note Art no Spare part no Equipment etc Elmo 3HAC5952 1 Motor unit axis 1 Includes motor pinion IRB 4400 Color ABB Orange 3HAC021724 001 Yaskawa Includes pinion Color Graphite White 3HAC021724 003 Yaskawa Includes pinion 21520431 11 O ring motor Continues on next page 216 Product man...

Page 217: ...ncluded in section Calibration on page 263 Calibration Pendulum Instruction CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page140 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 ...

Page 218: ...page 216 Remove the attachment screws and washers of the motor Note Check the position of the motor label before removing the motor The motor must be mounted back at the same position 6 Remove the motor 7 Refitting motor axis 1 The procedure below details how to refit the motor axis 1 Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply do not ...

Page 219: ...ipment on page 216 Apply flange sealing to the motor flange 7 Place the new motor in the gearbox 8 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 xx0300000155 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...

Page 220: ...eplace the gaskets if they are damaged 13 Reconnect all the connectors 14 Refit the cover of the connection box 15 Calibration is detailed in a separate calibration manual enclosed with the calibration tools Recalibrate the robot 16 General calibration information is included in section Calibration on page 263 DANGER Make sure all safety requirements are met when performing the first test run Thes...

Page 221: ...0000159 Motor axis 2 A Connection box B Attachment screws and washers C Required equipment Note Art no Spare part no Equipment etc Elmo 3HAC5954 1 Motor unit axis 2 Includes pinion IRB 4400 Color ABB Orange 3HAC021725 001 Yaskawa Includes pinion Color Graphite White 3HAC021725 003 Yaskawa Includes pinion 21520431 11 O ring Loctite 574 12340011 11 Flange sealing Continues on next page Product manua...

Page 222: ...aint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page140 Removal motor axis 2 The procedure below details how to remove the motor axis 2 Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot working area 1 xx02000...

Page 223: ...ressure supply do not turn off for Foundry Prime robots to the robot before entering the robot work ing area 1 CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 2 Note The motor units from Elmo and Yaskawa are not compatible 3 Check that the assembly surfaces are clean from paint lubricant etc 4 Make sure that the motor and the gearbox are not da...

Page 224: ...the motor before continuing the refit ting procedure 10 Shown in the figure Location of motor on page 221 Fit the other two attachment screws and washers 11 2 pcs M10x70 2 pcs M10x30 Tightening torque 60 Nm Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 114 Refill with oil 12 Shown in the figure Location of motor on page 221 Refit the connecti...

Page 225: ...rforming the first test run These are further detailed in the section First test run may cause injury or damage on page 27 17 Product manual IRB 4400 225 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 2 Replacement of motor axis 2 Continued ...

Page 226: ...0163 Motor axis 3 A Connection box B Attachment screws and washers motor C Required equipment Note Art no Spare part no Equipment etc Elmo 3HAC5954 1 Motor unit axis 3 Includes pinion IRB 4400 Color ABB Orange 3HAC021725 001 Yaskawa Includes pinion Color Graphite White 3HAC021725 003 Yaskawa Includes pinion 21520431 11 O ring Loctite 574 12340011 116 Flange sealing Continues on next page 226 Produ...

Page 227: ...dge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page140 Removal motor axis 3 The procedure below details how to remove the motor axis 3 Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot working area 1 DANGER Secure...

Page 228: ... air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot work ing area 1 CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 2 Note The motor units from ELMO and YASKAWA are not compatible 3 Check that the assembly surfaces are clean from paint lubricant etc 4 Make sure that the motor and the gearbox are ...

Page 229: ... on page 231 Note Adjust the motor before continuing the refit ting procedure 10 Shown in figure Location of motor on page 226 Fit the other two attachment screws and washers motor 11 M10x70 M10x30 Tightening torque 60 Nm Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 114 Refill with oil 12 Shown in the figure Location of motor on page 226 Ref...

Page 230: ...rforming the first test run These are further detailed in the section First test run may cause injury or damage on page 27 17 230 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 3 Replacement of motor axis 3 Continued ...

Page 231: ...akes These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below See chapter Circuit diagram on page 297 Circuit diagram CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page...

Page 232: ...ere is a narrow backlash Note There should always be a backlash but it should be as minimal as possible Measure the torque with the motor shaft in different positions The torque should be max 0 1 Nm on radius 50 mm more than meas ured before If the torque is more slightly loosen the screws a little and carefully knock the motor in the oppos ite direction then measure the torque again Check that th...

Page 233: ...otor unit axis 6 C Attachment screws and washers motor D Connection box E Required equipment Note Art no Equipment etc Content is defined in section Stand ard tools on page 291 3HAC17594 1 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below See chapter Circuit...

Page 234: ... Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 3 Draining is detailed in sections Oil change gearbox axis 4 on page 118 Oil change gearbox axis 5 and 6 all robot ver sions on page 121 Drain the oil from the gearbox 4 Remove the cover of the connection box 5 Disconnect all the connectors in the connection box 6 Shown in the figure Location of motors o...

Page 235: ... IRB 4400 xx0300000164 Motor unit axis 4 A Motor unit axis 5 B Motor unit axis 6 C Attachment screws and washers motor D Connection box E Required equipment Note Art no Spare part no Equipment etc Elmo 3HAC10603 1 Motor unit axis 4 Includes pinion IRB 4400 Color ABB Orange 3HAC021726 001 Yaskawa Includes pinion Color Graphite White 3HAC021726 003 Yaskawa Includes pinion Continues on next page Prod...

Page 236: ...he step by step instruc tions below See chapter Circuit dia gram on page 297 Circuit diagram Art no is specified in section Calibration on page 263 manual Calibration Pendulum In struction CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page140 Refitting motor axis 4 The procedure below ...

Page 237: ... radial direction so that the play is minimal within one motor revolu tion without the gear chewing 10 Shown in the figure Location of motor on page 235 Refit the motor with its attachment screws and washers motor 11 4 pcs M6x25 Tightening torque 15 Nm Detailed in section Oil change gearbox axis 4 on page 118 Refill with oil if drained 12 Part no is specified in Required equip ment on page 235 Che...

Page 238: ...erforming the first test run These are further detailed in the section First test run may cause injury or damage on page 27 18 238 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 6 Refitting of motor axis 4 Continued ...

Page 239: ...detailed view of the component and its position may be found in chapter Exploded views in Product manual spare parts IRB 4400 xx0300000164 Motor unit axis 4 A Motor unit axis 5 B Motor unit axis 6 C Attachment screws and washers motor D Connection box E Continues on next page Product manual IRB 4400 239 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 7 Refitting ...

Page 240: ...HAB1409 1 Measuring tool 24VDC 1 5A Power supply 2 pcs used to release the brakes in the motors for axes 4 and 5 These procedures include references to the tools re quired Other tools and proced ures may be required See references to these procedures in the step by step instructions be low See chapter Circuit diagram on page 297 Circuit diagram Art no is specified in section Calibration on page 26...

Page 241: ... 6 Connect to connector R3 MP4 MP5 24V pin 7 0V pin 8 Release the brakes in the motors for axes 4 and 5 by connecting the 24 VDC power supply 7 Place the new motor unit in the gearbox Do not damage the pinion or the gear wheel 8 Find the position of least play by turning the out going shaft for axis 4 in intervals of 90 one re volution in all to locate the area where the play for the motor axis 5 ...

Page 242: ... properly 15 Reconnect all the connectors 16 Refit the cover on the connection box 17 Calibration is detailed in a separ ate calibration manual enclosed with the calibration tools Recalibrate the robot 18 General calibration information is included in section Calibration on page 263 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in th...

Page 243: ...roduct manual spare parts IRB 4400 xx0300000164 Motor unit axis 4 A Motor unit axis 5 B Motor unit axis 6 C Attachment screws and washers motor D Connection box E Required equipment Note Art no Spare part no Equipment etc Elmo 3HAC10604 1 Motor unit axis 6 Includes pinion IRB 4400 Yaskawa 3HAC021728 001 Motor unit axis 6 Includes pinion IRB 4400 Continues on next page Product manual IRB 4400 243 3...

Page 244: ...e proced ures in the step by step instructions below See chapter Circuit dia gram on page 297 Circuit diagram Art no is specified in section Calibration on page 263 Calibration Pendulum In struction CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page140 Refitting motor axis 6 The proced...

Page 245: ...9 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 10 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 11 Push the motor in a radial direction so that the play is minimal within one motor revolution without the gear chewing 12 Shown in the figu...

Page 246: ...tion information is included in section Calibra tion on page 263 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the section First test run may cause injury or damage on page 27 20 246 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 7 8 Refitting of motor axis 6 Continued ...

Page 247: ...hapter Exploded views in Product manual spare parts IRB 4400 xx0300000174 Gearbox unit axes 1 3 spare part A Bottom plate B Attachment screws and washers gearbox unit C Sealing D Required equipment Note Art no Spare part no Equipment etc Does not include motors and lubricating oil 3HAC5948 1 Gearbox unit axes 1 3 IRB 4400 Replace if damaged 3HAC5479 2 Sealing Content is defined in section Standard...

Page 248: ...motors from the robot Info Illustration Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot working area 1 CAUTION The robot arm system weighs 245 kg All lifting accessories used must be sized accordingly 2 CAUTION The robot base weighs 130 kg All lifting accessories used must...

Page 249: ... both attachment points 9 Lift the gearbox unit together with the base and use the hoisting block to tip the complete assembly forward 90 10 xx0300000173 Place the assembly on a level surface and support it at position A according to the figure on the right CAUTION Make sure the unit is stable and rests securily before removing the lifting equipment 11 B Approximately 200 mm IRB 4400 all models Sh...

Page 250: ...tep DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply do not turn off for Foundry Prime robots to the robot before entering the robot working area 1 CAUTION The robot base weighs 130 kg All lifting accessories used must be sized accordingly 2 CAUTION The robot arm system weighs 245 kg All lifting accessories used must be sized accordingly 3 Continues on next p...

Page 251: ... the base with the attachment screws and washers gearbox unit 7 Attachment 14 pcs M16x80 12 9 UNBRAKO Tightening torque 260 Nm Reused screws may be used provid ing they are lubricated as detailed in Screw joints in the Product manual reference information before fitting Shown in the figure Location of gear box unit on page 247 Refit the bottom plate with its attachment screws 8 See section Removal...

Page 252: ...tailed in a separate calibration manual enclosed with the calibration tools Recalibrate the robot 16 General calibration information is in cluded in section Calibration on page 263 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page27 17 252 Product manual IRB 4400 3HAC022032...

Page 253: ...is defined in section Standard tools on page 291 3HAC17594 1 Standard toolkit These procedures include ref erences to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before rep...

Page 254: ...re Illustration adjust ing play on page 253 Remove the cover 3 Shown in the figure Illustration adjust ing play on page 253 Unlock the three screws 4 Rotate axis 4 to find the highest position of the gear on the upper arm tubular 5 3 pcs tightening torque 69 Nm Tighten the three screws again 6 Art no is specified in Required equipment on page 253 Apply flange sealing to the cover and refit it with...

Page 255: ...055 3 Cable strap 3HAC026759 001 Sikaflex 521FC Drill diameter 8 8 mm CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page140 Replacement of motor axes 1 3 The following procedure details how to replace motors axes 1 3 Note Action xx0600003111 Apply Sikaflex 521FC on both sides of the ga...

Page 256: ...e around the motor 3 A Sikaflex xx0600003113 Apply Sikaflex 521FC underneath the cover attachment screw heads 4 A Sikaflex Continues on next page 256 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 9 1 Repair routines Continued ...

Page 257: ...efore assembling a new cable harness Drill diameter 8 8mm Thread 1 8 pipe thread 1 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 Additional r A Air connection on motor cable box axis 4 6 Continues on next page Product manual IRB 4400 257 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights...

Page 258: ...he balancing device in the robot apply Mercasol on both side of the ear and both side of the washers 1 A Mercasol Replacement of air hose Required equipment 1 3 4 5 2 7 6 xx0600003342 Continues on next page 258 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 9 1 Repair routines Continued ...

Page 259: ...r the SMB box se step 1 and 2 in Replacement of air hose on page 260 140 mm A From the T plug connector to the stright plug connector in the SMB box 270 mm B 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 260 3050 mm C From the Y plug connector at axis 4 5 6 motors to the straight fitting in the m...

Page 260: ...connector to the straight fitting in the motor cover axis 2 365 mm M To the Bulkhead plug in the front plate 150 mm N Replacement of air hose The following procedure details how to replace the air hose Note Action Additional r 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 plu...

Page 261: ...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 4 xx0600003120 The hose continue through the lower arm and is connected to a Y plug connector at the upper arm housing 5 Continues on next page Product manual IRB 4400 261 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4...

Page 262: ...a Y plug connector and a T plug connector to the cable boxes 6 xx0600003122 xx0600003344 From the Y plug connector for the balancing cylinder to the elbow plug in the back of the balancing cylinder 7 262 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 4 Repair 4 9 1 Repair routines Continued ...

Page 263: ...tion counter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 269 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 The revolution counters must also be updated after the robot...

Page 264: ... load Absolute accuracy calibration focuses on pos itioning accuracy in the Cartesian coordinate system for the robot Absolute accuracy calibration option al 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 delivery ...

Page 265: ...bes the method and the different routines further 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 Application manual CalibWare Field 5 0 If a service o...

Page 266: ...400 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 xx0300000209 Punch axis 2 3HAB 1521 1 A Punch axis 3 3HAB 1522 1 B Continues on next page 266 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 5 Calibration 5 3 Synchronization marks and synchronization posi...

Page 267: ...ions of the marks as shown in the figure C Punch axis 5 3HAB 1524 1 D Product manual IRB 4400 267 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 5 Calibration 5 3 Synchronization marks and synchronization position for axes Continued ...

Page 268: ...nes will handle the calibration movements automatically and these might be different from the positive directions shown below Manual 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 xx0200000089 268 Product manual IRB 4400 3HAC022032 001 Rev...

Page 269: ...n Note Action Select axis by axis motion mode 1 See Synchronization marks and synchron ization position for axes on page 266 Jog the manipulator to align the synchron ization marks IRB 140 1400 2400 4400 6600ID 6650ID 6640ID Axes 5 and 6 must be positioned together 2 Step 2 Updating the revolution counter with the TPU on page 270 BaseWare 4 0 When all axes are positioned update the revolution coun...

Page 270: ...be wrong even if the motor calibration data is correct try to rotate the axis one turn update the revolution counter and check the synchronization marks again try both directions if needed Step 2 Updating the revolution counter with the TPU Use this procedure to update the revolution counter with the TPU BaseWare 4 0 Note Action Press the button Miscellaneous then ENTER to select the service windo...

Page 271: ... the Revolution Counter Update window 6 Not required At this point it is recommended that the revolution counter values are saved to a diskette 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator positioning which in turn may cause damage or injury Check the synchronization position very carefully after each update 8 How to perform the check is detailed in ...

Page 272: ...ABB menu tap Calibration xx1500000942 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question xx1500000943 Continues on next page 272 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 5 Calibration 5 5 Updating revolution counters Continued ...

Page 273: ...s 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 selected revolution counters and removes the tick from the list of axes 6 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn ma...

Page 274: ...eck that the synchronization marks for the axes align correctly If they do not update the revolution counters 3 Using a MoveAbsJ instruction Use this procedure to create a program that runs all the robot axes to their synchronization position Note Action On ABB menu tap Program editor 1 Create a new program 2 Use MoveAbsJ in the Motion Proc menu 3 Create the following program MoveAbsJ 0 0 0 0 0 0 ...

Page 275: ...ters 4 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis 1 2 or 3 3 Manually run the robots axes to a position where the axis position value read on the FlexPendant is equal to zero 4 See Synchronization marks and synch...

Page 276: ...tion on IRB 4400 the stainless steel metal ring on axis 4 need to be removed Illustration A B C xx0600003124 Upper arm A Stainless steel ring B Hose clamp C 276 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 5 Calibration 5 7 Additional calibration instruction IRB 4400 ...

Page 277: ...s Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance ...

Page 278: ...o organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 278 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 279: ...rocedures in the step by step in structions 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 ...

Page 280: ...rom a safe distance and somewhat from above 2 DANGER The hole must be cut as specified in the figure Pieces of the spring can be thrown out from the cylinder at high speed if the hole is cut larger than specified 3 Use a cutting torch with a long shaft 80 mm 250 mm xx0700000730 Cut a hole in the housing as shown in the figure 4 Use a cutting torch with a long shaft Outer spring cut at least five c...

Page 281: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 4400 281 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All r...

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Page 283: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 4400 283 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 284: ...015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment o...

Page 285: ...R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 4400 285 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 7 Reference information 7 2 Applicable standards Continued ...

Page 286: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 286 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 287: ...uld 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 dimensions...

Page 288: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 289: ...ning torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 4400 289 3HAC022032 001 Rev...

Page 290: ...sory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 1300 kg All lifting accessories used must be sized accord ingly 290 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB...

Page 291: ... in the following table This way the tools required are the sum of the standard toolkit and any tools listed in the instruction Contents standard toolkit Tool Qty 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 1 Puller bar 2 KM nut KM10 KM17 1 Lifting hoist 1 Cutting pliers 1 Torque wrench 10 470 Nm 1 Product manual IRB 4400...

Page 292: ...tion Note Art no Description 68080011 LP Angle bracket 3HAC13908 9 Calibration bracket 3HAC13908 4 Calibration tool ax1 Includes one sensor 6369901 347 Levelmeter 2000 kit 3HAC13908 5 Measuring pin 68080011 GM Sensor fixture 3HAC0392 1 Sensor plate 3HAC13908 1 Sync adapter Calibration equipment Calibration Pendulum The following table specifies the calibration equipment needed when calibrating the...

Page 293: ...ting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 4400 293 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting ...

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Page 295: ...ews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 4400 295 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 8 Spare Part lists 8 1 Spare part lists and illustrations ...

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Page 297: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 298: ...am IRB 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram IRB 14000 3HAC056159 002 Circuit diagram IRB 910SC 298 Product manual IRB 4400 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved 9 Circuit diagram 9 1 Circuit diagrams Contin...

Page 299: ...D danger levels 39 detergents approved 113 requirements 113 direction of axes 268 E enabling device 29 environmental information 277 ESD damage elimination 32 sensitive equipment 32 external safety devices 25 F fire extinguishing 21 FlexPendant jogging to calibration position 275 MoveAbsJ instruction 274 updating revolution counters 272 foundation requirements 54 G gearboxes location of 114 grease...

Page 300: ...gnals in manual 39 symbols 39 symbols on robot 41 test run 27 working range 28 safety equipment mechanical stop axis 2 76 position switch axis 3 79 safety fence 18 safety risk electric parts 30 hot parts 33 hydraulic system 34 installation 24 oil change 37 operational disturbance 24 pneumatic system 34 service work 24 voltage 30 safety signals in manual 39 safety standards 284 safety zones 18 scal...

Page 301: ...justing 93 W weight 52 robot 59 66 157 159 163 164 167 168 188 195 196 200 203 248 250 290 working range restricting axis 2 76 restricting axis 3 79 Z zero position checking 274 Product manual IRB 4400 301 3HAC022032 001 Revision Q Copyright 2004 2018 ABB All rights reserved Index ...

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Page 304: ...265 N 4349 BRYNE Norway Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC022032 001 Rev Q en Copyright 2004 2018 ABB All rights reserved ...

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