3HAC022032 PM IRB 4400-En

ROBOTICS
Product manual
IRB 4400
Trace back information:
Workspace 23A version a6
Checked in 2023-03-06
Skribenta version 5.5.019
Product manual
IRB 4400/60
IRB 4400/L10
M2000, IRC5
Document ID: 3HAC022032-001

Revision: W
© Copyright 2004-2023 ABB. All rights reserved.

Specifications subject to change without notice.
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damage 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 ABB.
Original instructions.

Table of contents
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation, M2000/M2000A ......................................................................................... 14
Product documentation, IRC5 .......................................................................................................... 15
How to read the product manual ...................................................................................................... 17
1 Safety 19
1.1 Safety information ............................................................................................. 19
1.1.1 Limitation of liability ................................................................................. 19
1.1.2 Requirements on personnel ...................................................................... 20
1.2 Safety signals and symbols ................................................................................. 21
1.2.1 Safety signals in the manual ...................................................................... 21
1.2.2 Safety symbols on manipulator labels ......................................................... 23
1.3 Robot stopping functions .................................................................................... 29
1.4 Safety during installation and commissioning ......................................................... 30
1.5 Safety during operation ...................................................................................... 33
1.6 Safety during maintenance and repair ................................................................... 34
1.6.1 Safety during maintenance and repair ......................................................... 34
1.6.2 Emergency release of the robot axes .......................................................... 37
1.6.3 Brake testing .......................................................................................... 38
1.7 Safety during troubleshooting .............................................................................. 39
1.8 Safety during decommissioning ........................................................................... 40
2 Installation and commissioning 41

2.1 Introduction to installation and commissioning ....................................................... 41
2.2 Installation and operational requirements for Foundry Prime robots ............................ 42
2.2.1 Shut-down periods .................................................................................. 46
2.3 Unpacking ....................................................................................................... 47
2.3.1 Pre-installation procedure ......................................................................... 47
2.3.2 Working range ........................................................................................ 51
2.3.3 The unit is sensitive to ESD ....................................................................... 54
2.4 On-site installation ............................................................................................ 55
2.4.1 Lifting robot with roundslings .................................................................... 55
2.4.2 Manually releasing the brakes ................................................................... 58
2.4.3 Orienting and securing the robot ................................................................ 61
2.4.4 Fitting equipment on the robot ................................................................... 64
2.4.4.1 Mounting equipment .................................................................... 64
2.4.5 Loads fitted to the robot, stopping time and braking distances ......................... 67
2.5 Restricting the working range .............................................................................. 68
2.5.1 Axes with restricted working range ............................................................. 68
2.5.2 Mechanically restricting the working range of axis 1 ...................................... 69
2.5.3 Mechanically restricting the working range of axis 2 ...................................... 72
2.5.4 Unlimited working range ........................................................................... 75
2.5.5 Risk of tipping/stability ............................................................................. 77
2.6 Electrical connections ........................................................................................ 78
2.6.1 Robot cabling and connection points .......................................................... 78
2.6.2 Customer connection on robot ................................................................... 80
2.7 Additional installation, Foundry Prime ................................................................... 83
2.7.1 Installation of IRB 4400 in a water jet application ........................................... 83
2.7.2 Commissioning (Foundry Prime) ................................................................ 87
2.8 Start of robot in cold environments ...................................................................... 88
2.9 Test run after installation, maintenance, or repair .................................................... 89
3 Maintenance 91
3.1 Introduction ...................................................................................................... 91
3.2 Introduction for Foundry Prime robots ................................................................... 92
Product manual - IRB 4400 5

3HAC022032-001 Revision: W
Table of contents
3.3 Maintenance schedule ....................................................................................... 93

3.3.1 Specification of maintenance intervals ........................................................ 93
3.3.2 Maintenance schedule ............................................................................. 94
3.4 Inspection activities ........................................................................................... 96
3.4.1 Inspecting information labels ..................................................................... 96
3.4.2 Inspecting Signal lamp (option) .................................................................. 98
3.4.3 Inspection of mechanical stop, axis 1 .......................................................... 100
3.4.4 Inspection of air hoses (Foundry Prime) ...................................................... 102
3.4.5 Inspection of surface treatment (Foundry Prime) ........................................... 104
3.5 General maintenance activities ............................................................................ 105
3.5.1 Replacing the SMB battery ........................................................................ 105
3.5.2 Cleaning the IRB 4400 .............................................................................. 107
3.6 Changing and inspecting oil ................................................................................ 111
3.6.1 Type of lubrication in gearboxes ................................................................ 111
3.6.2 Inspection of oil levels .............................................................................. 112
3.6.3 Oil change, gearbox axis 4 ........................................................................ 115
3.6.4 Oil change, gearbox axis 5 and 6 (all robot versions) ..................................... 118
3.6.5 Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) .................................... 121
3.7 Service Information System, M2000 ...................................................................... 124
3.7.1 Using the SIS system ............................................................................... 124
3.7.2 Description of Service Information System (SIS) ........................................... 125
3.7.3 SIS system parameters ............................................................................ 128
3.7.4 Setting the SIS parameters ....................................................................... 129
3.7.5 Reading the SIS output logs ...................................................................... 130
3.7.6 Exporting the SIS data ............................................................................. 131
4 Repair 133
4.1 Introduction ...................................................................................................... 133
4.2 General procedures ........................................................................................... 134
4.2.1 Mounting instructions for bearings ............................................................. 134
4.2.2 Mounting instructions for sealings .............................................................. 136
4.2.3 Cut the paint or surface on the robot before replacing parts ............................ 139
4.2.4 Performing a leak-down test ...................................................................... 141
4.2.5 The brake release buttons may be jammed after service work ......................... 142
4.3 Complete robot ................................................................................................. 143
4.3.1 Replacement of cable harness, axes 1-3 ...................................................... 143
4.3.2 Replacement of cable harness, axes 4-6 ...................................................... 148
4.3.3 Replacement of complete arm system ......................................................... 155
4.4 Upper arm ....................................................................................................... 160
4.4.1 Replacement of complete upper arm ........................................................... 160
4.4.2 Replacement of wrist unit ......................................................................... 165
4.4.3 Replacement of arm house unit, axis 4 ........................................................ 169
4.4.4 Replacement of mechanical stop, axis 4 ...................................................... 172
4.4.5 Replacement of signal cabling, upper arm (option 042) ................................... 175
4.4.6 Measuring the play, axis 5 ......................................................................... 179
4.4.7 Measuring the play, axis 6 ......................................................................... 182
4.5 Lower arm ....................................................................................................... 185
4.5.1 Replacement of lower arm ........................................................................ 185
4.5.2 Replacement of tie rod ............................................................................. 189
4.5.3 Replacement of parallel arm / Replacement of bearing ................................... 193
4.6 Frame and base ................................................................................................ 197
4.6.1 Replacement of balancing device ............................................................... 197
4.6.2 Replacement of serial measurement unit ..................................................... 205
4.6.3 Replacement of the brake release board ...................................................... 209
4.6.4 Replacement of mechanical stop pin, axis 1 ................................................. 213
4.7 Motors ............................................................................................................ 215
4.7.1 Replacement of motor, axis 1 .................................................................... 215
6 Product manual - IRB 4400

Table of contents
4.7.4 Adjustment of motors, axes 1-3 .................................................................. 230

4.7.5 Removal of motor, axes 4, 5 and 6 .............................................................. 232
4.7.6 Refitting of motor, axis 4 ........................................................................... 234
4.8 Gearboxes ....................................................................................................... 246
4.8.1 Replacement of gearbox unit, axes 1-2-3 ..................................................... 246
4.8.2 Adjusting play on axis 4, intermediate gear .................................................. 252
4.9 Additional repair routines for Foundry Prime .......................................................... 254
4.9.1 Repair routines ....................................................................................... 254
5 Calibration 263
5.1 When to calibrate ............................................................................................. 263
5.2 Calibration methods ........................................................................................... 264
5.3 Synchronization marks and synchronization position for axes ................................... 266
5.4 Calibration movement directions for all axes .......................................................... 268
5.5 Updating revolution counters on IRC5 robots ......................................................... 269
5.6 Checking the synchronization position .................................................................. 274
5.7 Calibrating with Calibration Pendulum method ....................................................... 276
5.8 Calibrating with Wrist Optimization method ........................................................... 277
5.9 Additional calibration instruction, IRB 4400 ............................................................ 279
6 Decommissioning 281
6.1 Introduction to decommissioning ......................................................................... 281
6.2 Environmental information .................................................................................. 282
6.3 Decommissioning of balancing device ................................................................... 284
6.4 Scrapping of robot ............................................................................................. 286
7 Reference information 287

7.1 Introduction ...................................................................................................... 287
7.2 Applicable standards ......................................................................................... 288
7.3 Unit conversion ................................................................................................. 290
7.4 Screw joints .................................................................................................... 291
7.5 Weight specifications ......................................................................................... 294
7.6 Standard tools .................................................................................................. 295
7.7 Special tools .................................................................................................... 296
7.8 Lifting accessories and lifting instructions .............................................................. 297
8 Spare Part lists 299

8.1 Spare part lists and illustrations ........................................................................... 299
9 Circuit diagram 301

9.1 Circuit diagrams ................................................................................................ 301
Index 303

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Overview of this manual

About this manual
This manual contains instructions for
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The manual also contains reference information for all procedures detailed in the
manual.
Usage
This manual should be used during
• installation, from lifting the robot to its work site and securing it to the
foundation to making it ready for operation
• maintenance work
• repair work.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope

The manual covers covers all variants and designs of the IRB 4400. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety, service Safety information
Installation and commissioning Information about installation of the robot.
Maintenance Information about maintenance work, including mainten-
ance schedules.
Repair Information about repair work.
Calibration information Procedures that does not require specific calibration
equipment. General information about calibration.
Continues on next page

Continued
Chapter Contents
Decommissioning Environmental information about the robot and its compon-
ents.
Reference information Useful information when performing installation, mainten-
ance or repair work (lists of necessary tools, reference
documents, safety standards)
Part list Complete list of robot parts, shown in the partlist
Exploded views Detailed illustrations of the robot with reference numbers
to the part list.
Circuit diagram Reference to the circuit diagram for the robot.
References
Document name Document ID Note

Product specification - IRB 4400 3HAC9117-1
Product manual, spare parts - IRB 4400 3HAC049107-001
Circuit diagram - IRB 4400/4450S 3HAC9821-1
Safety manual for robot - Manipulator and IRC5 3HAC031045-001 M2004
or OmniCore controller i
Product manual - IRC5 3HAC021313-001 M2004
IRC5 with main computer DSQC 639.
Product manual - IRC5 3HAC047136-001
IRC5 with main computer DSQC1000.
Operating manual - IRC5 with FlexPendant 3HAC050941-001 M2004
Operating manual - Calibration Pendulum 3HAC16578-1
Application manual - CalibWare Field 3HAC030421-001
Technical reference manual - Lubrication in gear- 3HAC042927-001
boxes
Operating manual - Service Information System 3HAC050944-001
Application manual - Additional axes and stan- 3HAC051016-001 M2004
dalone controller
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
Revision Description
- First edition.
Replaces previous manuals:
• Installation and Commissioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Model M2004 implemented.

Continued
A Chapter Safety, service replaced with chapter Safety.
Chapter Calibration replaced with chapter Calibration information.
Removed chapter Calibration, M2004.
Section Document references is completed with article numbers for calibration
manuals.
B Yaskawa motors been added.
C Robot model IRB 4450S added.
D Foundry Prime (Water jet application) added.
E The protection type Clean Room is added.
Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
F Content updated in chapter/section:
• Section What is an emergency stop? added to chapter Safety
• Maintenance/Maintenance schedule: Interval for replacement of battery
pack changed
• Maintenance/Cleaning of robot
G Missing spare part in chapter Spare parts, section Upper arm, axes 4-6, added:
• Item 29, Gear axis 6
H This revision includes the following updates:
• Inspection of surface treatment added to maintenance schedule (Foundry
Prime)
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagram on page 301.
• List of applicable safety standards updated.
• Decommissioning chapter added.
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning.
Safety signals in the manual:
• New safety labels on the manipulator.
• Revised terminology: robot replaced with manipulator.
J This revision includes the following updates:
• All information about IRB 4400-45, IRB 4400-L10, IRB 4400-L30, IRB
4400-S and IRB 4450S is removed from the manual.
• A new block, about general illustrations, added in section How to read
the product manual on page 17.
• Some general tightening torques have been changed/added, see updated
values in Screw joints on page 291.
• Added information about batteries.
• 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 page 111.
• A new SMB unit and battery is introduced, with longer battery lifetime.
K This revision includes the following updates:
• The SMB unit backup battery of type NiCad, is no longer available as a
spare part. Therefor removed from this manual.
• Added information about risks when scrapping a decommissioned robot,
see Scrapping of robot on page 286.
• Spare parts and exploded views are not included in this document but
delivered as a separate document. See Product manual, spare parts - IRB
4400.
• The variant IRB 4400/L10 is added.

Continued
L This revision includes the following updates:
• Minor corrections.
M This revision includes the following updates:
• Turning disc fixture is removed from special tools for Levelmeter calib-
ration.
• Information about mounting guard plate at push button unit for brake
release added.
N Published in release R16.2. The following updates are done in this revision:
• Corrections due to updates in terminology.
• Location of labels figure added.
P Published in release R17.2. The following updates are done in this revision:
• Information about coupled axes in Updating revolution counters on IRC5
robots on page 269.
• Caution about removing metal residues added in sections about SMB
boards.
• Information about minimum resonance frequency added.
• Updated list of applicable standards.
• Drawing view for extra equipment holes updated.
• Section Start of robot in cold environments on page 88 added.
• 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 142.
• Updated the description of dimensions (pos A) Mounting equipment on
page 64).
• Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
Q Published in release R18.1. The following updates are done in this revision:
• Added sections in General procedures on page 134.
• Safety restructured.
• Updated spare part number brake release board unit (was DSQC563, is
DSQC1050).
• Information about myABB Business Portal added.
• Added Nickel in Environmental information.
R Published in release R18.2. The following updates are done in this revision:
• Updated spare part number of gearbox unit for axes 1-3.
S Published in release 19B. The following updates are made in this revision:
• New touch up color Graphite White available. See Cut the paint or surface
on the robot before replacing parts on page 139.
• Levelmeter 2000 kit (6369901-347) no longer available.
T Published in release 20B. The following updates are made in this revision:
• Clarified and added information in mounting instructions for rotating
sealings, see Mounting instructions for sealings on page 136.
• Added information about Wrist Optimization and Pendulum Calibration
in calibration chapter.
• Replaced article number and name of grease, previously 3HAB3537-1.
U Published in release 22A. The following updates are made in this revision:
• Text regarding fastener quality is updated, see Fastener quality on
page 66.
• Updated information about Gleitmo treated screws, see Screw joints on
page 291.
• Removed information about position switches as they are no longer
available.

Continued
V Published in release 22B. The following updates are made in this revision:
• Added article numbers for the power and signal cables connecting the
manipulator with the control cabinet.
W Published in release 23A. The following updates are made in this revision:
• Changed article number for air hose from 3HAC026526-001 to
3HAC062050-001 in section Replacement of air hose.

Product documentation, M2000/M2000A
Product documentation, M2000/M2000A

General
The complete product documentation kit for the M2000 robot system, including
controller, robot and any hardware option, consists of the manuals listed below:
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (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 complete listing of all available software manuals is available from ABB.
Controller hardware option manual

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

Product documentation, IRC5

Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Troubleshooting.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• 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.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.

Continued
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.

How to read the product manual
How to read the product manual

Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.
References to required equipment

The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 19.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.

1 Safety
1.1.1 Limitation of liability
1 Safety
1.1 Safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
Spare parts and equipment

ABB supplies original spare parts and equipment which have been tested and
approved for their intended use. The installation and/or use of non-original spare
parts and equipment can negatively affect the safety, function, performance, and
structural properties of the robot. ABB is not liable for damages caused by the use
of non-original spare parts and equipment.

1 Safety
1.1.2 Requirements on personnel
1.1.2 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.
Personal protective equipment

Use personal protective equipment, as stated in the instructions.

1 Safety
1.2.1 Safety signals in the manual
1.2 Safety signals and symbols
Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
WARNING Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in serious
injury.
ELECTRICAL Signal word used to indicate a potentially hazardous

SHOCK situation related to electrical hazards which, if not
avoided, could result in serious injury.
CAUTION Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in slight
injury.
ELECTROSTATIC Signal word used to indicate a potentially hazardous

DISCHARGE (ESD) situation which, if not avoided, could result in severe
damage to the product.
NOTE Signal word used to indicate important facts and

conditions.

1 Safety
Continued
Symbol Designation Significance

TIP Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.

1 Safety
1.2.2 Safety symbols on manipulator labels
Introduction to symbols
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 23.
The information labels can contain information in text.
Symbols on safety labels
Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
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.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.
xx0900000839

1 Safety
Continued
Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813
Before disassembly, see product manual
xx0900000816
Do not disassemble
Disassembling this part can cause injury.
xx0900000815
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000814
Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808

1 Safety
Continued
Symbol Description
Tip risk when loosening bolts
The robot can tip over if the bolts are not securely fastened.
xx0900000810
xx1500002402
Crush
Risk of crush injuries.
xx0900000817

1 Safety
Continued
Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)
xx0900000818
!
3HAC 4431-1/06
xx1300001087
Moving robot
4 6 The robot can move unexpectedly.
3 5
1
xx0900000819
xx1000001141
2 3
xx1500002616

1 Safety
Continued
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
Chain sling with shortener
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824

1 Safety
Continued
Symbol Description
No mechanical stop
xx1000001144
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.
xx0900000825
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.
xx0900000826
Shut off with handle

Use the power switch on the controller.
xx0900000827
Do not step
Warns that stepping on these parts can cause damage to the
parts.
xx1400002648

1 Safety
1.3 Robot stopping functions
1.3 Robot stopping functions
Protective stop and emergency stop

The protective stops and emergency stops are described in the product manual
for the controller.
For more information see:
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted Controller

1 Safety
1.4 Safety during installation and commissioning
National or regional regulations

The integrator of the robot system is responsible for the safety of the robot system.
The integrator is responsible that the robot system is designed and installed in
accordance with the safety requirements set forth in the applicable national and
regional standards and regulations.
The integrator of the robot system is required to perform a risk assessment.
Layout
The robot integrated to a robot system shall be designed to allow safe access to
all spaces during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing
the working space.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand
the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum
speed.
• The maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed
in the section Robot motion in the product specification for the respective
manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall be considered.
Hazards due to noise emission from the robot needs to be considered.
Consider hazards from other equipment in the robot system, for example, that
guards remain active until identified hazards are reduced to an acceptable level.
Allergenic material
See Environmental information on page 282 for specification of allergenic materials
in the product, if any.
Securing the robot to the foundation

The robot must be properly fixed to its foundation/support, as described in the
respective product manual.
When the robot is installed at a height, hanging, or other than mounted directly on
the floor, there will be additional hazards.

1 Safety
Continued
Electrical safety
Incoming mains must be installed to fulfill national regulations.
The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.
Wherever possible, power on/off or rebooting the robot controller shall be performed
with all persons outside the safeguarded space.
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.
Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.
Other hazards
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
The risk assessment should also consider other hazards arising from the
application, such as, but not limited to:
• Water
• Compressed air
• Hydraulics
End-effector hazards require particular attention for applications which involve
close human collaboration with the robot.

1 Safety
Continued
Pneumatic or hydraulic related hazards
Note
The pressure in the complete pneumatic or hydraulic systems must be released

before service and maintenance.
All components in the robot system that remain pressurized after switching off
the power to the robot must be marked with clearly visible drain facilities and a
warning sign that indicates the hazard of stored energy.
Loss of pressure in the robot system may cause parts or objects to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.
Verify the safety functions

Before the robot system is put into operation, verify that the safety functions are
working as intended and that any remaining hazards identified in the risk
assessment are mitigated to an acceptable level.

1 Safety
1.5 Safety during operation
1.5 Safety during operation
Automatic operation
Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.
Unexpected movement of robot arm
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
WARNING
equipment.

1 Safety
1.6.1 Safety during maintenance and repair
1.6 Safety during maintenance and repair
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Hazards due to stored mechanical energy in the manipulator for the purpose of
counterbalancing axes must be considered before maintenance or repair.
Never use the robot as a ladder, which means, do not climb on the controller,
manipulator, including motors, or other parts. There are hazards of slipping and
falling. The robot might be damaged.
Make sure that there are no loose screws, turnings, or other unexpected parts
remaining after work on the robot has been performed.
When the work is completed, verify that the safety functions are working as
intended.
Hot surfaces
Surfaces can be hot after running the robot, and touching these may result in burns.
Allow the surfaces to cool down before maintenance or repair.
Allergic reaction
Warning Description Elimination/Action

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
Allergic reaction
Gearbox lubricants (oil or grease)

When handling oil, grease, or other chemical substances the safety information of
the respective manufacturer must be observed.
Note
Take special care when handling hot lubricants.

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

1 Safety
Continued

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox
Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Al-
ways use the type of oil specified
for the product.
Do not mix types of oil
Oil residues might be present in Make sure that protective gear
a drained gearbox and spilled like goggles/protective visor,
when separating a motor and gloves and arm protection are
gearbox during repair. always worn during this activity.
Put oil absorbent cloth or paper
Oil residues
at appropriate locations to catch
any oil residues.
Warm oil drains quicker than Run the robot before changing
cold oil. the gearbox oil, if possible.
Heat up the oil

The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume

1 Safety
Continued

For lifetime reasons always drain
as much oil as possible from the
gearbox. The magnetic oil plugs
will gather residual metal chips.
Contaminated oil in
gearboxes
Hazards related to batteries

Under rated conditions, the electrode materials and liquid electrolyte in the batteries
are sealed and not exposed to the outside.
There is a hazard in case of abuse (mechanical, thermal, electrical) which leads
to the activation of safety valves and/or the rupture of the battery container. As a
result under certain circumstances, electrolyte leakage, electrode materials reaction
with moisture/water or battery vent/explosion/fire may follow.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Operating conditions, robot on page 50.
See safety instructions for the batteries in Material/product safety data
sheet - Battery pack (3HAC043118-001).
WARNING
WARNING
equipment.
Related information
See also the safety information related to installation and operation.

1 Safety
1.6.2 Emergency release of the robot axes
1.6.2 Emergency release of the robot axes
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
• Shut-down periods on page 46.
The robot may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.
Increased injury
Before releasing the brakes, make sure that the weight of the manipulator does
not result in additional hazards, for example, even more severe injuries on a trapped
person.
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.

1 Safety
1.6.3 Brake testing
1.6.3 Brake testing
When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be verified as described
below:
1 Run each axis to a position where the combined weight of the manipulator
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 manipulator does not change position as the motors are switched off,
then the brake function is adequate.
Note
It is recommended to run the service routine BrakeCheck as part of the regular

maintenance, see the operating manual for the robot controller.
For robots with the option SafeMove, the Cyclic Brake Check routine is
recommended. See the manual for SafeMove in References on page 10.

1 Safety
1.7 Safety during troubleshooting
1.7 Safety during troubleshooting
General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.
DANGER
Troubleshooting on the controller while powered on must be performed by

personnel trained by ABB or by ABB field engineers.
A risk assessment must be done to address both robot and robot system specific
hazards.
WARNING
WARNING
equipment.
Related information
See also the safety information related to installation, operation, maintenance, and
repair.

1 Safety
1.8 Safety during decommissioning
1.8 Safety during decommissioning
General
See section Decommissioning on page 281.
If the robot is decommissioned for storage, take extra precaution to reset safety
devices to delivery status.
WARNING
WARNING
equipment.

2 Installation and commissioning
2.1 Introduction to installation and commissioning

2.1 Introduction to installation and commissioning
General
This chapter contains assembly instructions and information for installing the IRB
4400 at the working site.
See also the product manual for the robot controller.
The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.
Safety information
Before any installation work is commenced, all safety information must be observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any installation
work.
Note
Always connect the IRB 4400 and the robot to protective earth and residual
current device (RCD) before connecting to power and starting any installation
work.

2.2 Installation and operational requirements for Foundry Prime robots
Introduction
Robots with protection type Foundry Prime are specially designed to work in harsh
environments. To ensure that the protection offers the best reliability, special
measures are required during installation and operation. It is required that the
environmental and application conditions are fulfilled and that the special
maintenance activities and intervals for the Foundry Prime protected robot are
followed.
Fluids in the vicinity of the robot

If fluids that can cause rust formation, for example, water etc., are used in the
vicinity of the robot it is required to add rust inhibitor to the fluid or take other
measures to prevent rust on unpainted joints or other unprotected surfaces of the
robot.
Activity to lubricate gearboxes cavities and gears

Run each axis on high speed at least once per hour. This activity will lubricate the
gearbox cavities and gears, which reduces the risk for corrosion due to
condensation in the 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 included) must be installed in the air supply system to monitor the supply
of air pressure in order to secure a correct pressure. See Pressurizing equipment
on page 43 for equipment specifications.
Note
The overpressure must be kept at 0.2 - 0.3 ± 0.0 bar during 24 hours independent
of Motors On/Off mode, start-up, and shut down periods.
WARNING
Do not to exceed the maximum pressure of 0.3 bar. If the air pressure exceeds
the specified, it can lead to damage to the gearbox or brake failure in the motors
which may cause the robot arms to fall down, leading to personal injury or physical
damage.

Continued
WARNING
If the pressurized air contains oil, it could result in a brake failure in the motors
and cause the robot arms to fall down, leading to personal injury or physical
damage.
Note
To secure the supply of air pressure, use a pressure sensor.
Air quality for pressurizing of robot

The air must be dry and clean, such as instrument air. The following table describes
the air specifications.
Parameter Value
Dew point <+2°C at 6 bar
Solid particle size <5 microns
Oil content <1 ppm (1 mg/m 3 )
Air flow >200 L/min
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:
Equipment Description
Pressure sensor Festo SDE1-series
Pressure regulator Festo LRP-series
Connect air hose to over pressure limiter unit
Note
ABB recommends the air pressure to be set at maximum 0.3 bar.

Continued
xx1700000565
Precautionary measures
Note
It is strictly forbidden to expose any part of the robot to direct high pressure water
jet! The sealing joints between the moving parts on the wrist must not be exposed
to high pressure water.
Rebounding high pressure water jet must be avoided. ABB recommends using
a tool design with integrated covers 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 damage in the
paint.

Continued
Sensitive points IRB 4400

Illustration shows points that are particularly sensitive to water spray.
A C
xx0800000462
A Inside lower arm

B Cable package
C Wrist

2.2.1 Shut-down periods
2.2.1 Shut-down periods
Shut-down periods
During shut-down periods the cleaning cell must be ventilated out (aired out). This
reduces the risk that moister is sucked into gearboxes during cooling down. It
gives the robot the possibility to dry as the rust inhibition effect normally gets
reduced after some time.
Ventilate and air out the cell during and after shut-downs:
• The cell must be ventilated during shut-down until the atmospheric humidity
in the cell has reached the same level as the surrounding 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 detergent or water without
rust inhibitor can give an accelerated corrosion on some robot components.
• The overpressure must be kept at 0.2 - 0.3 ± 0.0 bar during 24 hours
independent of Motors On/Off mode, start-up and shut-down periods.

2.3.1 Pre-installation procedure
2.3 Unpacking
Introduction
This section is intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.
Prerequisites for installation personnel

Installation personnel working with an ABB product must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/maintenance/repair work
• conform to all national and local codes.
Checking the pre-requisites for installation
Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.
Note
Stop unpacking and contact ABB if transport damages are found.
4 Clean the unit with a lint-free cloth, if necessary.

5 Make sure that the lifting accessory used (if required) is suitable to handle the weight
of the robot as specified in: Weight, robot on page 47
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 49
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 50
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 48
• Protection classes, robot on page 50
• Requirements, foundation on page 49
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 77
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 55
11 Install required equipment, if any.
Weight, robot
The table shows the weight of the robot.
Robot model Weight
IRB 4400 1300 kg

Continued
Note
The weight does not include tools and other equipment fitted on the robot.
Loads on foundation, robot

The illustration shows the directions of the robots stress forces.
The directions are valid for all floor mounted, suspended and inverted robots.
Txy
Fz
Fxy
Tz
xx1100000521
Fxy Force in any direction in the XY plane

Fz Force in the Z plane
Txy Bending torque in any direction in the XY plane
Tz Bending torque in the Z plane
The table 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
Force Endurance load (in operation) Max. load (emergency stop)

Force xy ± 7500 N ± 9000 N
Continued
Force Endurance load (in operation) Max. load (emergency stop)

Force z +9500 ± 2000 N +9500 ± 3000 N
Torque xy ± 14000 Nm ± 16000 Nm
Torque z ± 2000 Nm ± 4000 Nm
Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.5 Flat foundations give better repeatability of the
surface resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
In order to compensate for an uneven surface,
the robot can be recalibrated during installation.
If resolver/encoder calibration is changed this
will influence the absolute accuracy.
Maximum tilt -
Minimum resonance - The value is recommended for optimal perform-
frequency ance.
Note Due to foundation stiffness, consider robot mass
including equipment. i
It may affect the For information about compensating for founda-
manipulator life- tion flexibility, see the application manual of the
time to have a controller software, section Motion Process
lower resonance Mode.
frequency than
recommended.
i The minimum resonance frequency given should be interpreted 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, even if the frequency is well below
the stated frequency. The robot should be mounted as rigid as possibly to the floor.
Disturbances from other machinery will affect the robot and the tool accuracy. The robot has
resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified,
although somewhat damped by the servo control. This might be a problem, depending on the
requirements from the applications. If this is a problem, the robot needs to be isolated from the
environment.
Storage conditions, robot

The table shows the allowed storage conditions for the robot:
Parameter Value
Minimum ambient temperature -25° C
Maximum ambient temperature +55° C
Maximum ambient temperature (less than 24 hrs) +70° C
Maximum ambient humidity 95% at constant temperature
(gaseous only)

Continued
Operating conditions, robot

The table shows the allowed operating conditions for the robot:
Parameter Value
Minimum ambient temperature +5° C
Maximum ambient temperature +45° C
Maximum ambient humidity 95% at constant temperature
Protection classes, robot

The table shows the available protection types of the robot, with the corresponding
protection class.
Protection type Protection class I
Manipulator, protection type Standard IP54
Manipulator, protection type Foundry Prime IP67, steam washable

2.3.2 Working range
2.3.2 Working range
Introduction to robot motion
Axis Type of motion Range of movement

1 Rotation motion + 165° to - 165°
2 Arm motion + 95° to - 70°
3 Arm motion + 65° to - 60°
4 Rotation motion + 200° to - 200°
5 Bend motion + 120° to - 120°
6 Turn motion + 400° to - 400°
+ 200 i rev. ii to - 200 rev. Max. iii
i + 183 rev to - 183 rev valid for IRB 4400/L10
ii rev. = Revolutions
iii The default 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
140 880 300

Pos 1
(150)
Pos 0
232
Pos 5
890
2140
Pos 6
1720
Pos 2
680
Pos 3
Pos 4
290
370 200
390 530
(1223) 732
1955
xx1100000592

2.3.2 Working range
Continued
Positions at wrist center (mm) and angle (degrees):

Position no (see Position (mm) X Position (mm) Z Angle (degrees) Angle (degrees)
figure above) Axis 2 Axis 3
0 1080 1720 0 0
1 887 2140 0 -30
2 708 836 0 65
3 1894 221 95 -60
4 570 -126 95 40
5 51 1554 -70 40
6 227 1210 -70 65
IRB 4400/L10
Pos 1
85 1500 300
(150)
Pos 5
Pos 0
148
2450
Pos 6
890
1720
680
Pos 2
Pos 3
390 530
905
Pos 4
300 200
(1477) 1070
2547
xx1300002627
Positions at wrist center (mm) and angle (degrees):

0 1700 1720 0 0

2.3.2 Working range
Continued
1 1424 2450 0 -30
2 970 274 0 65
3 2401 -135 95 -60
4 500 -786 95 24
5 588 1864 -70 40
6 845 1265 -70 65

2.3.3 The unit is sensitive to ESD
2.3.3 The unit is sensitive to ESD
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Safe handling
Use one of the following alternatives:
• Use a wrist strap.
Wrist straps must be tested frequently to ensure that they are not damaged
and are operating correctly.
• Use an ESD protective floor mat.
The mat must be grounded through a current-limiting resistor.
• Use a dissipative table mat.
The mat should provide a controlled discharge of static voltages and must
be grounded.

2.4.1 Lifting robot with roundslings
2.4 On-site installation
General
Lift the robot using lifting straps and a traverse crane according to this section.
Required equipment
Equipment Art. no. Note

Crane Lifting capacity: 2100kg (max. load at 90°)
Round slings, 2 m Lifting capacity/sling: 1100kg
2 pcs for IRB 4400
Lifting lugs Type: OBK 7-8
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.

Continued
Lifting, robot version, IRB 4400

The lifting equipment is attached to the robot as shown in the figure below.
0°
xx0300000245
Lifting instruction, IRB 4400

The procedure below details how to lift the complete robot.
Action Information
1 Release the brakes manually, to make it Detailed in section Manually releasing the
possible to alter the positions of the arms. brakes on page 58.
2 Move the robot to the calibration position.

Continued
Action Information
3 Move the lower arm backwards to get bal-
ance, according to angle specified to the
right.
0°
xx0300000245
4 Attach the round slings to the special eye Shown in the figure Lifting, robot version,
bolts on the gearbox unit for axes 2 and 3 IRB 4400 on page 56.
using lifting lugs. The roundsling and lifting lug dimensions
must comply with the applicable stand-
ards specified in Required equipment on
page 55.
5 Lift the robot to its installation site.
Make sure the slings do not rub against any
sharp edges!

2.4.2 Manually releasing the brakes
General
The section below describes how to release the holding brakes of each axis' motor.
This can be done in one of three ways:
• using the push-button when the robot is connected to the controller.
• using the push-button on the robot with an external power supply.
• using an external voltage supply directly on the respective brake.
DANGER
When releasing the holding brakes with push-buttons, the robot must be properly
attached!
DANGER
When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways!
Make sure no personnel is near or beneath the robot arm!
Using the push-button when the robot is connected to the controller

This procedure details how to release the holding brakes with push-buttons, when
the robot is connected to the controller.
Action Note
1 The internal brake release unit is located
at the base of the robot.
xx0300000198
2 The brake release unit is equipped with

six buttons for controlling the axes brakes.
The buttons are numbered according to
the numbers of the axes.

Continued
Action Note
3 Release the holding brake on a particular
axis by pressing the corresponding button
on the push-button unit and keeping it
depressed.
4 The brake will function again as soon as
the button is released.
Using the push-button on the robot with an external power supply

This procedure details how to release the holding brakes with the push-buttons,
when the robot is not connected to the controller.
Action Note
1 Connect an external 24VDC power supply to
the connector R1.MP on the robot base, as
shown in the figure to the right.
Note! Be careful not to interchange the 24V
and 0V pins.
If they are mixed up, damage can be caused
to the brake release unit and the intergrated
quenching circuits.
xx0200000022
DANGER!
Incorrect connections can cause all brakes
to be released simultaneously!
xx0300000200
Connect to connector R1.MP:

• 0V: pin B14 or B15
• +24V: pin B16
2 Release the holding brake on a particular The brake release unit is equipped with
axis by pressing the corresponding button six buttons for controlling the axes
on the push-button unit and keeping it de- brakes. The buttons are numbered accord-
pressed. ing to the numbers of the axes.
See the previous figure.
3 The brake will function again as soon as the
button is released.

Continued
Using an external voltage supply directly on the respective brake

This procedure details how to release the holding brake of a specific axis by
supplying external voltage directly on the brake.
Action Note
1 Every axis has a holding brake built into the Make the connection to the current motor
axis motor. This holding brake may be re- according to the Circuit Diagram.
leased by connecting 24VDC power supply See chapter Circuit diagram on page 301.
directly to one of the connectors in the motor.
DANGER
When power is connected directly to the

brake cable, the brake will be released imme-
diately when the power is switched on.
This may cause some unexpected robot
movements!
2 Connect an external 24 VDC power supply Axes 1, 2 and 3:

to the motor, according to the figures. Pos 2: +24 V
Note
Be careful not to interchange the 24V and 0V

pins!
If they are mixed up, damage can be caused Pos 5: 0 V
to the intergrated quenching circuits.
WARNING
Incorrect connections can cause all brakes

to be released simultaneously! xx1400001984

2.4.3 Orienting and securing the robot
General
This section details how to orient and secure the robot to the base plate after fitting
it to the foundation.
Securing parts/facts
The table below specifies the type of securing screws and washers to be used to
secure the robot to the base plate/foundation.
Securing parts/fact Dimension/art. no. Amount/Note
Securing screws, oiled M20 3 pcs
Washers Thickness: 3 mm 3 pcs
Outer diameter: 36 mm
Inner diameter: 21 mm
Guide sleeves 21510024-169 2 pcs
Added to the rear bolt holes,
to allow the same robot to be
re-mounted without program
adjustments.
Tightening torque 350 - 400 Nm Oiled screws
Level surface requirements
xx0300000251

Continued
Hole configuration and dimensions

The illustration below shows the hole configuration and hole dimensions of the
robot base, seen from below.
The cut x-x shows the dimension of the rear bolt holes, where the guide sleeves
may be used.
xx0300000252
A Rear bolt holes

B Center line, axis 1
Orienting and securing the robot

The procedure below details how to orient and secure the robot to the base plate
after fitting the plate to the foundation.
Action Info/Illustration
1
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.
2
CAUTION
The IRB 4400 robot weighs 1300 kg.

All lifting accessories used must be sized
accordingly!
3 Lift the robot. Detailed in section Lifting robot with

roundslings on page 55.
4 Move the robot to the vicinity of the installa-
tion site.

Continued
5 Fit two guide sleeves to the rear bolt holes Art. no. is specified in Securing parts/facts
in the base. on page 61.
Shown in the figure Hole configuration
and dimensions on page 62.
6 Guide the robot gently using M20 screws
while lowering it into its mounting position.
7 Fit the securing screws and washers in the Specified in Securing parts/facts on
base attachment holes. page 61.
Attachment holes shown in the figure
Hole configuration and dimensions on
page 62.
8 When bolting a mounting plate or frame to a
concrete floor, follow the general instructions
for expansion-shell bolts.
The screw joint must be able to withstand the
stress loads defined in section Loads on
foundation, robot on page 48.

2.4.4.1 Mounting equipment
2.4.4 Fitting equipment on the robot
Upper arm and base

The robot is supplied with tapped holes on the upper arm and on the base for
mounting extra equipment.
IRB 4400/60
A
250 175 A 150 300

H B
(A)
D
300
390
D
150
25
50
20º
340 B
144 54
B-B
Max. 15 kg (B)
(C)
15
29.5 29.5
106
View H
110
200
D-D
(D)
A-A (E)
195
(F) C
Ø100
120º (3x)
(G)
15º C
C-C
xx1300000001
Pos Description
A M8 (x2) Used if option 218-6 is chosen, depth
of thread 9 mm
B M8 (x7) Depth of thread 14 mm
C 571 mm

Continued
Pos Description
D M6 (2x) tapped depth 12 mm
E Max. 5 kg at max handling weight
F M8 (x3) R= 92 mm, depth 16 mm (if option 34-
1 is chosen these holes are occupied)
G Max. 35 kg
IRB 4400/L10
A
250 175 150 300
(A) (B) B
390
385
. 77
25
20º 150
B-B Max. 15 kg
B
110 115 54
1221
M5 (2x)
300
D=240 22
78 110
43 Max. 2 kg
A-A
(C)
195 C
D=100
120º (3x) Max. 35 kg
15º
C
C-C
xx1300002625
Pos Description
A M6 (x2) Depth of thread 15 mm
B M8 (x3) Depth of thread 14 mm
C M8 (x3) R= 92 mm, depth of thread 16 mm (If
option 34-1 is chosen these holes are occu-
pied)

Continued
Note
Maximum loads must never be exceeded!
Tool flange
IRB 4400/60
A
+0.015
D=8 -0 Ø0.05 A
A
8 30º M10 (6x)
R50
60º
60
º
D=125--0.063
+0.045
0
0 D=63
º
60
60
º
9 60º
A
A-A
xx1100000602
IRB 4400/L10
A +0.012
D=6 -0 H7
Ø0.05 B
30º B
8
M6 (6x)
x
º 5
H8
R=25
60
h8
+0.039
-0
-0.046
D=31,5
+0
D=63
A
7
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.
Fastener quality
When fitting tools on the tool flange, only use screws with quality 12.9. For other
equipment use suitable screws and tightening torque for your application.

2.4.5 Loads fitted to the robot, stopping time and braking distances
2.4.5 Loads fitted to the robot, stopping time and braking distances
General
Any loads mounted on the robot must be defined correctly and carefully (with
regard to the position of center of gravity and mass moments of inertia) in order
to avoid jolting movements and overloading motors, gears and structure.
CAUTION
Incorrectly defined loads may result in operational stops or major damage to the
robot.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must 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 listed in References
on page 10.

2.5.1 Axes with restricted working range
2.5 Restricting the working range
2.5.1 Axes with restricted working range
General
When installing the robot, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space
should be limited.
The working range of the following axes may be restricted:
• Axis 1, hardware (mechanical stop)
• Axis 2, hardware (mechanical stop).
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.

2.5.2 Mechanically restricting the working range of axis 1
Mechanically restricting the working range

The working range of axis 1 can be restricted mechanically by fitting additional
mechanical stops to the base, as detailed in this section.
Required equipment
Equipment, etc. Art. no. Note

Mechanical stop, axis 1 3HAB3833-1 Includes 2 additional stop lugs, 8 attachment
screws, 8 plain washers and a label
Attachment screw 9ADA183-71 4 pcs/lug, included in 3HAB3833-1
M12x60
Washer 9ADA312-9 4 pcs/lug, included in 3HAB3833-1
13x24x2.5
Standard toolkit 3HAC17594-1 Content is defined in section Standard tools
on page 295.
Other tools and procedures These procedures include references to the
may be required. See refer- tools required.
ences to these procedures
in the step-by-step instruc-
tions below.

Continued
Additional stops
The additional stops are fitted as shown in the figure.
xx0300000258
B Mechanical stop lugs

C Attachment screw and washer
D Max. working range with stop lugs (250°)
E Stop pin
F Min. working range with stop lugs (127°)
Fitting, mechanical stop axis 1

How to fit the additional mechanical stop to the base is described in the procedure.
Mounting instructions are also supplied with the kit.
Action Note
1 Determine the position of the stop lugs and See the figure Additional stops on
mark the hole positions on the base. page 70 for guidance.
2 Drill Ø10.2 mm to a maximum depth of 45
mm and tap with M12 thread. Min. thread
depth 35 mm.

Continued
Action Note
3 Fit the stop lugs firmly with attachment Specified in Required equipment on
screws and washers according to the figure page 69.
Additional stops on page 70. M12x60, tightening torque: 82 Nm, oil
lubrication.

Mechanically restricting the working range

The working range of axis 2 can be restricted mechanically by fitting additional
mechanical stops (spacers and dampers) to the lower arm and gearbox unit axis
1-3, as detailed in this section. Note that the system parameter configuration must
also be adjusted (Upper joint bound and Lower joint bound for the type Arm in the
topic Motion).
Required equipment
Equipment, etc. Spare part no. Art. no. Note

Mechanical stop, axis 2 3HAC4225-1 Includes spacers, dampers,
attachment screws and nuts.
Spacer (damper) 3HAB9185-1
Spacer 3HAC3962-1
Standard toolkit 3HAC17594-1 Content is defined in section
Contents, standard toolkit on
page 295.
Other tools and procedures These procedures include
may be required. See refer- references to the tools re-
ences to these procedures quired.
tions below.

Continued
Additional stops
The additional mechanical stops (spacers and dampers) are fitted to the lower arm
and the gearbox unit, as shown in the figure below.
xx0300000260
A View A of the lower arm

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

Continued
Working range
The working range of axis 2 can be restricted according to the table below.
Working range Damper, qty Spacer, qty
+95° / -70° - -
+95° / -40° - 2
+95° / -10° 2 2
+65° / -70° 2 -
+65° / -40° 2 2
+65° / -10° 4 2
+35° / -70° 4 -
+35° / -40° 4 2
+35° / -10° 6 2
+5° / -70° 6 -
+5° / -40° 6 2
+5° / -10° 8 2
• Each damper is fitted with: 2 attachment screws and 2 hexagon nuts.

• Each spacer is fitted with: 1 attachment screw and 1 hexagon nut.
Fitting, mechancial stop axis 2

The procedure below details how to fit the additional mechanical stop to the lower
arm and the gearbox unit.
Mounting instructions are also supplied with the kit.
1 Determine the working range restriction. See Working range on page 74.
2 Fit both the spacers to either side of the Shown in the figure Additional stops on
gearbox unit, with the attachment screws and page 73.
nuts, spacer. Art. no. is specified in Required equip-
ment on page 72.
Attachment screw: 1 pc/spacer, M16x70.
Tightening torque: 156 Nm.
3 Fit the dampers to both sides of the lower Shown in the figure Additional stops on
arm with the attachment screws and nuts, page 73.
damper. Art. no. is specified in Required equip-
ment on page 72.
Attachment screws: 2 pcs/damper,
M10x60. Tightening torque: 49 Nm.

2.5.4 Unlimited working range
Resetting the work area for an axis

The function Resetting the work area for an axis, included in Advanced Motions
3.0, can also be used for axis 4. To enable this function, the mechanical stop on
axis 4 should be removed. Follow the procedure below to dismantle the mechanical
stop.
A more detailed view of the component and its position may be found in chapter
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.
xx0300000176
A Mechanical stop axis 4

B Damper axis 4
C Attachment screws, mechanical stop

Continued
Removal of mechanical stop, axis 4

The procedure below details how to remove the mechanical stop of axis 4, to enable
the function Resetting the work area for an axis.
WARNING
When the damper is removed from axis 4, the axis does not have a mechanical
stop! If the robot is provided with cabling on the upper arm, the cabling can be
damaged when the function Resetting the work area for an axis is used, or if the
robot is jogged uncalibrated.
1
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.
2 Loosen the attachment screws, mech stop Shown in the figure Location of mechan-
and remove the mechanical stop, axis 4. ical stop, axis 4 on page 75.
3 Slowly rotate axis 4 until the damper is visible
through the hole.
4 Remove the damper.
5 Refit the mechanical stop to the axis 4 with 4 pcs, M8x16. Tightening torque: 24 Nm.
its attachment screws.

2.5.5 Risk of tipping/stability
2.5.5 Risk of tipping/stability
Risk of tipping
Do not change the robot position before securing it to the foundation.
The shipping position is the most stable position.
Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.
0°
xx0300000245
WARNING
The robot will be mechanically unstable if not properly secured to the foundation.

2.6.1 Robot cabling and connection points
2.6 Electrical connections
Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.
CAUTION
Connect the male and female connectors perfectly aligned horizontally to avoid
any kind of tilt or skew.
CAUTION
Verify that the robot serial number is according to the number(s) in the Declaration
of Incorporation (DoI).
Main cable categories

All cables between the robot and controller are divided into the following categories:
Cable category Description
Robot cables Handles power supply to and control of the robot's motors
as well as feedback from the serial measurement board.
Specified in the table Robot cables on page 78.
Customer cables (option) Handles communication with equipment fitted on the robot
by the customer, low voltage signals and high voltage power
supply + protective ground.
See the product manual for the controller, see document
number in References on page 10.
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet (OmniCore con-
to the robot motors. trollers)
Robot cable, signals Transfers resolver data from XS2 R1.SMB
and power supply to the serial (OmniCore con-
measurement board. trollers)
Robot cable, power
Art. no. Description Option no. i

3HAC2512-1 Control cable power 7 m Standard: 210-2 and 287-4
Clean room: 210-2 and 287-1

Continued
Art. no. Description Option no. i

3HAC8182-1 Control cable power 7 m Foundry: 210-2 and 287-3
Wash: 210-2 and 287-5
Wash: 210-3 and 287-5
Wash: 210-4 and 287-5
Wash: 210-5 and 287-5
i The option number depends on the protection type of the manipulator.
Robot cable, signals
Cable Art. no.

Robot cable signal, shielded: 7 m 3HAC7998-1
Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.
A
B
xx1600002016
A Diameter
B Diameter x10

2.6.2 Customer connection on robot
Location of customer connection

For the connection of extra equipment to the robot, cables and air hose are
integrated into the robot´s cabling, and there is one FCI UT071823SH44N and one
FCI UT071412SH44N connector on the rear part of the upper arm.
The customer connections are located on the robot as shown in the figure.
xx0300000270
A R1.CP, R1.CS, Air R1/4"

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

Connections to the:
• air hose (R1/4" ) is located on the rear part of the upper arm and at the base.
Max. 8 bar. Inner diameter of the air hose: 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.
Connection Connector Art. no. Content
set
R1.CP/CS R1.CP/CS 3HAC12275-1 • socket for area of 0.14 - 0.5 mm 2
(protection • compression gland for cables,
Standard) diameter 2 x 12 mm
• key pin
R1.CP/CS F R1.CP/CS 3HAC12276-1 • socket for area of 0.14 - 0.5 mm 2
(protection • compression gland for cables,
Foundry diameters 10 mm and 12 mm
Prime) • key pin

Continued
Connection Connector Art. no. Content

set
R2.CS/R3.CS R2.CS/R3.CS 3HAC12327-1 • pins for cable area of 0.13 - 0.25
mm 2
• reduction hose, bottled-shaped
• reduction hose, angled
R2.CP/R3.CP R2.CP/R3.CP 3HAC12326-1 • pins for cable area of 0.13 - 0.25
mm 2
• reduction hose, bottled-shaped
• reduction hose, angled
Power supply connections on the robot
Signal name Customer Ter- Customer Contact Customer Contact on robot base
minal Controller on Upper arm, R2 (cable between robot and controller
not supplied)
CPA XT6.1 R2.CP.A RI.CP/CS.A1
CPB XT6.2 R2.CP.B RI.CP/CS.B1
CPC XT6.3 R2.CP.C RI.CP/CS.C1
CPD XT6.4 R2.CP.D RI.CP/CS.D1
CPE XT6.5 R2.CP.E RI.CP/CS.A2
CPF XT6.6 R2.CP.F RI.CP/CS.B2
- R2.CP.G (Earth) RI.CP/CSP Earth
XT6.H R2.CP.H (Key pin)
CPJ XT6.7 R2.CP.J RI.CP/CS.C2
CPK XT6.8 R2.CP.K RI.CP/CS.D2
CPL XT6.9 R2.CP.L RI.CP/CS.A3
CPM XT6.10 R2.CP.M RI.CP/CS.B3
Signal connections on the robot
not supplied)
CSA XT5.1 R2.CS.A R1.CS/CP.B5
CSB XT5.2 R2.CS.B R1.CS/CP.C5
CSC XT5.3 R2.CS.C R1.CS/CP.D5
CSD XT5.4 R2.CS.D R1.CS/CP.A6
CSE XT5.5 R2.CS.E R1.CS/CP.B6
CSF XT5.6 R2.CS.F R1.CS/CP.C6
CSG XT5.7 R2.CS.G R1.CS/CP.D6
CSH XT5.8 R2.CS.H R1.CS/CP.A7
CSJ XT5.9 R2.CS.J R1.CS/CP.B7
CSK XT5.10 R2.CS.K R1.CS/CP.C7
CSL XT5.11 R2.CS.L R1.CS/CP.D7

Continued
not supplied)
CSM XT5.12 R2.CS.M R1.CS/CP.A8
CSN XT5.13 R2.CS.N R1.CS/CP.B8
CSP XT5.14 R2.CS.P R1.CS/CP.C8
CSR XT5.15 R2.CS.R R1.CS/CP.D8
CSS XT5.16 R2.CS.S R1.CS/CP.A9
CST XT5.17 R2.CS.T R1.CS/CP.B9
CSU XT5.18 R2.CS.U R1.CS/CP.C9
CSV XT5.19 R2.CS.V R1.CS/CP.D9
CSW XT5.20 R2.CS.W R1.CS/CP.A10
CSX XT5.21 R2.CS.X R1.CS/CP.B10

2.7.1 Installation of IRB 4400 in a water jet application
2.7 Additional installation, Foundry Prime
General
Robots delivered with the Foundry Prime protection are specially designed to work
in water jet cleaning cells with 100% humidity and alkaline detergent. To ensure
that the protection offers the best reliability, some measures are needed during
installation of the robot according to the procedures below.
Note
For best reliability, it is also of highest importance that the special maintenance
instructions for the Foundry Prime robot are followed and documented.
Commissioning
• Never switch off the overpressure in motors and serial measurement
compartment during cooling down of robot after it has been switched off.
• When turning off an cleaning cell we recommend that the humid air inside a
cell is ventilated out, to avoid that the humid air is sucked into e.g. gearboxes
due to the raised vacuum when cooled down.
Environmental conditions
Humidity 100%
Washing detergent with pH <9.0
Washing detergent must contain rust inhibitor and
be approved by ABB.
Cleaning bath temperature <60°C, used in a typical waterjet clean-
ing application at suitable speed.
Air specification for pressurizing of robot

The air must be dry and clean, such as instrument air. Following table details the
air specification.
Dew point <+2°C at 6 bar
Solid particle size <5 microns
Oil content <1 ppm (1 mg/m3)
Pressure to robot 0.2 - 0.3 bar
WARNING
If the pressurized air contains oil, it could result in a brake failure in the motors
and cause the robot arms to fall down, leding to personal injure or physical
damage.

Continued
WARNING
If the air pressure exceeds the specified, it could result in a brake failure in the
motors and cause the robot arms to fall down, leding to personal injure or physical
damage.
Note
To secure sufficient air pressure, it is recommended to use a pressure sensor.
Pressurize the motors and serial measurement board cavity

The robots are prepared with hoses to the motors and the serial measurement
board cavity to enable pressurizing of them.
WARNING
The robot must be pressurized also when it is switch off, to avoid that the humid
environmental air is sucked into the motors when cooling down.
1 Connect a compressed air hose to air con-
nector on robot base, see illustration.
xx1500002398
Dimension: G1/8, d=6mm

2 Protect the screws on the Harting connectors Do this when the controller cables are
on the robot base from corrosion with Mer- connected.
casol.
3 Pressurize the robot. See Air specification for pressurizing of
robot on page 83 for correct pressure.
4 Inspect the air system. See Inspection of air hoses (Foundry
Prime) on page 102.
Protecting from high pressure water
WARNING
No part of the robot are allowed to be exposed to direct high pressure jet of water.
The sealings between the moving parts on the wrist must not be exposed to
direct or rebounding high-pressure jet of water.

Continued
Protecting the wrist joints

The sealings between the moving parts on the wrist must not be exposed to direct
high-pressure water. We recommend that the gripper include a shield that prevents
direct water flush on the sealing surfaces of the wrist. The sealings are pointed
out in the illustration below.
A
B
C
xx0600003108
A Axis 5, bearing support side

B Axis 5, bearing gear side
C Axis 6, mounting flange - gear house
Protecting the wrist flange from corrosion

The mounting surface on the wrist flange is protected with grease. The joint between
the wrist flange and the tool and the screw holes on the wrist flange must be
protected.
1 After mounting the tool, clean the following
surfaces from grease:
• the visible surface (not painted)
• the rear end of the screw holes and
end of screws.
B
A
xx0600003109
A screw holes and screws

B unpainted surface
2 Protect these surfaces with Mercasol.

Continued
3 Before running the robot in a water jet Inspection of air hoses (Foundry Prime)
cleaning cell: on page 102
• perform a inspection of the pressure
in motors and SMB cavity.

2.7.2 Commissioning (Foundry Prime)
2.7.2 Commissioning (Foundry Prime)
General
The following should be taken in consideration when running a robot in a water jet
application cell:
CAUTION
Never switch off the overpressure in motors and serial measurement compartment
during cooling down of robot after it has been switched off.
Note
To reduce the risk for corrosion due to condensation in gearboxes, it is 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.

2.8 Start of robot in cold environments
2.8 Start of robot in cold environments
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
Problems with starting the robot

Event message from Motion Supervision
Use this procedure if an event message indicates a problem with Motion supervision
at start-up. More information about Motion Supervision is found in Technical
reference manual - System parameters.
Action Note
1 Turn off Motion Supervision.
2 Start the robot.
3 When the robot has reached normal working temper-
ature, the Motion Supervision can be turned on
again.
Robot stopping with other event message

Use this procedure if the robot is not starting.
Action Note
1 Start the robot with its normal program but The speed can be regulated with the
with reduced speed. RAPID instruction VelSet.
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:
Work cycles AccSet Speed/velocity
3 Work cycles 20, 20 v100 (100 mm/s)
5 Work cycles 40, 40 v400 (400 mm/s)
5 Work cycles 60, 60 v600 (600 mm/s)
5 Work cycles 100, 100 v1000 (1000 mm/s)
More than 5 Work cycles 100, 100 Max.
If the program consists of large wrist movements, it is possible that the reorientation
velocity, which is always high in predefined velocities, needs to be included in the
ramping up.

2.9 Test run after installation, maintenance, or repair
2.9 Test run after installation, maintenance, or repair
Safe handling
Use the following procedure after installation, maintenance, or repair, before
initiating motion.
DANGER
Initiating motion without fulfilling the following aspects, may increase the risk for
injury or cause damage to the robot.
Action
1 Remove all tools and foreign objects from the robot and its working area.
2 Verify that the robot is properly secured to its position by all screws, before it is powered
up.
3 Verify that any safety equipment installed to secure the position or restrict the robot
motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Verify that all safety equipment is installed, as designed for the application.
6 Verify that no personnel are inside the safeguarded space.
7 If maintenance or repair has been done, verify the function of the part that was main-
tained.
8 Verify the application in the operating mode manual reduced speed.
Collision risks
CAUTION
When programming the movements of the robot, always identify potential collision
risks before initiating motion.

3 Maintenance
3.1 Introduction
3 Maintenance
3.1 Introduction
Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB
4400.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different 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 19 before performing any service
work.
The maintenance must be done by qualified personnel in accordance with the
safety requirements set forth in the applicable national and regional standards and
regulations.
Note
If the IRB 4400 is connected to power, always make sure that the IRB 4400 is
connected to protective earth and a residual current device (RCD) before starting
any maintenance work.
• Robot cabling and connection points on page 78.

3 Maintenance
3.2 Introduction for Foundry Prime robots
3.2 Introduction for Foundry Prime robots
Introduction
The Foundry Prime robots are designed for installation and operation in very hard
environments. Misuse of the robots, as well as poor installation, cleaning,
maintenance, and repair can be harmful for the functioning of the robot.
To eliminate these risks appropriate equipment and procedures are required when
installing, cleaning, maintaining, and repairing ABB Foundry Prime robots.
An extended maintenance program including service activities and schedule is
required.
Cleaning and maintenance of robots with Foundry Prime protection shall be
performed by trained personnel.
Specific maintenance activities and intervals for Foundry Prime

The Foundry Prime robots have specific maintenance activities and intervals
compared to standard robots:
• More comprehensive
• More frequent
• Sample activities for check of 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 cavities and gears, which reduce the risk for corrosion due
to condensation in gearboxes.
Non-predictable situations
Non-predictable situations also give rise to inspections of the robot. Any damage
must be attended to immediately.
Note
Repair damages on painted surfaces as soon as possible. Use the touch-up kit
3HAC035355-001 for Foundry Prime protection.
Warranty claims
Warranty claims for defect products due to misuse or failure to fulfil operational
and maintenance requirements will not be approved.

3 Maintenance
3.3.1 Specification of maintenance intervals
3.3 Maintenance schedule
3.3.1 Specification of maintenance intervals
Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the IRB 4400:
• Calendar time: specified in months regardless of whether the system is
running or not.
• Operating time: specified in operating hours. More frequent running 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 M2004 is further described in the Operating manual - Service
Information System.
Robots with the functionality Service Information System activated can show active
counters in the device browser in RobotStudio, or on the FlexPendant.

3 Maintenance
3.3.2 Maintenance schedule
General
The robot must be maintained regularly to ensure proper function. The maintenance
activities and intervals are specified in the table below.
Unexpected situations that arise prompt inspection of the robot. Any damage must
be attended to immediately!
The inspection intervals do not specify the life of each component.
Activities and intervals (protection Standard)

The table below specifies the required maintenance activities and intervals.
Maintenance Equipment Interval Detailed in section
activity
Replacement Battery pack, meas- 36 months or Replacing the SMB battery on
urement system of battery low page 105
type RMU101 or alert i
RMU102 (3-pole bat-
tery contact)
Replacement Battery pack, meas- Battery low Replacing the SMB battery on
urement system with alert ii page 105
2-pole battery con-
tact, e.g. DSQC633A
Replacement Signal cabling, upper 12,000 hrs Replacement of signal cabling, up-
arm (option 042) per arm (option 042) on page 175
Inspection Mechanical stop, axis Regularly iii Inspection of mechanical stop, axis
1 1 on page 100
Change Oil, gearbox axis 4 12,000 hrs iv Oil change, gearbox axis 4 on
page 115
Change Oil, gearbox axes 5 12,000 hrs iv Oil change, gearbox axis 5 and 6
and 6 (all robot versions) on page 118
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 to be replaced.
See the replacement instruction for more details.
ii The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the
robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime
can be extended with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.
iii Must be replaced if bent!
iv The gearboxes are lubricated for life, which corresponds to 40,000 hours of operation if the robot
is operating with an ambient temperature of less than 40° C. If the temperature is higher, the oil
must be changed!

3 Maintenance
Continued
Activities and intervals (protection Foundry Prime)

Robots working with water jet cleaning and that have the special tightness for this
application require special maintenance for proper function. The maintenance must
be done according to the maintenance schedule in the Product Manual and the
following additional maintenance.
Maintenance Equipment Interval Detailed in section
activity
Inspection Cable harness 6 months Replacement of cable har-
Replacement If required i ness, axes 1-3 on page 143
or Replacement of cable
harness, axes 4-6 on
page 148
Inspection Mechanical stop, ax- Regularly ii Inspection of mechanical
is 1 stop, axis 1 on page 100
Inspection Air hoses 6 months Inspection of air hoses
(Foundry Prime) on page 102
Inspection Wrist rust protection 6 mths Protecting the wrist flange
from corrosion on page 85
Inspection Surface treatment 6 months iii Inspection of surface treat-
ment (Foundry Prime) on
page 104
Inspection Balancing device 6 months
Changing Gear oil axes 1-6 6,000 hrs iv Changing and inspecting oil
on page 111
Replacement Battery pack, meas- 36 months or battery Replacing the SMB battery
urement system of low alert v on page 105
type RMU101 or
RMU102 (3-pole bat-
tery contact)
Replacement Battery pack, meas- Battery low alert vi Replacing the SMB battery
urement system with on page 105
2-pole battery con-
tact, e.g. DSQC633A
i Parts that need to be changed according to the maintenance schedule are not covered by warranty.
ii Must be replaced if bent!
iiiDamage to painted surfaces must be repaired as soon as possible to avoid corrosion.
iv The gearboxes are lubricated for life, which corresponds to 40,000 hours of operation if the robot
is operating with an ambient temperature of less than 40° C. If the temperature is higher, the oil
must be changed!
v 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 to be replaced.
See the replacement instruction for more details.
vi The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the
robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime
can be extended with a battery shutdown service routine. See Operating manual - IRC5 with

3 Maintenance
3.4.1 Inspecting information labels
3.4 Inspection activities
Location of information labels

The figure shows the location of the information labels to be inspected.
M H
E
F
K J
N D
H L
C H A
G
B
xx1600001280
A Instruction - Brake release unit

B Warning sign - Heat (3 pcs)
C Warning sign - Balancing cylinder
D Rating label
E ABB logotype (2 pcs)
F ABB logotype (2 pcs)
G Protection class logotype
H Warning sign - Symbol of flash (5 pcs)
J UL/UR label
K Calibration label (4 pcs)
L Instruction plate - Lifting of robot
M Designation sign

3 Maintenance
Continued
Required equipment
Equipment Spare part number Note

Labels See Spare Part lists on
page 299.
Inspecting labels
Use this procedure to inspect the labels on the robot.
Action Note
1
DANGER
Turn off all:

ing area.
2 Check all labels. See the figure in Location of information

labels on page 96.
3 Replace any missing or damaged labels.

3 Maintenance
3.4.2 Inspecting Signal lamp (option)
Location of signal lamp

Signal lamp is an option.
Located as shown in the figure.
B C D
xx0800000290
A Signal lamp
B R3.H1 +, R3.H2 -
C R2.CP
D R2.CS
Required equipment
Equipment Note
Signal lamp For spare parts no. see Spare parts - Spare
parts options in Product manual, spare
parts - IRB 2600.
Standard toolkit Content is defined in section Standard tools
on page 295.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.
Additional equipment - Foundry Prime

Rust preventive 3HAC034903-001 Mercasol
Sikaflex 521FC 3HAC026759-001
Loctite 574 12340011-116
Brush
Foundry Prime touch up kit 3HAC035355-001

3 Maintenance
Continued
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 139.
Inspecting signal lamp

Use this procedure to inspect the function of the signal lamp.
Note
If the signal lamp is damaged, it shall be replaced!
Action Note
1 Check that the signal lamp is lit when motors
are put in operation ("MOTORS ON").
2 If the signal lamp is not lit, continue tracing
the fault with the steps below.
3
DANGER
Turn off all:

ing area.
4 Check whether the signal lamp is broken. If

so, replace.
5 Check the cable connections.
6 Measure the voltage in connectors, motor 24V
axis 3.
7 Check the cabling. If a fault is detected, re-
place.
8 Seal and paint the joints that have been
opened. Also repair possible damages of the
special Foundry Prime paint coat of the robot.
See Cut the paint or surface on the robot be-
fore replacing parts on page 139.

3 Maintenance
3.4.3 Inspection of mechanical stop, axis 1
Location of mechanical stop

The mechanical stop on axis 1 is located on the frame as shown in the figure.
xx0300000182
A Mechanical stop pin, axis 1

B Set screw
Required equipment
Equipment, etc. Spare part no. Note

Mechanical stop, axis 1 3HAB3647-1
Standard toolkit Content is defined in section
Contents, standard toolkit on
page 295.
Other tools and procedures may be These procedures include ref-
required. See references to these erences to the tools required.
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!

3 Maintenance
Continued
Action Information
1
DANGER
Turn off all:

• air pressure supply (do not turn off for Foundry
Prime robots!)
to the robot, before entering the robot working area.
2 Check regularly that the stop pin is not bent or dam-

aged in any other way.
3 Removal/refitting of the
Note mechanical stop is detailed in
section Fitting, mechanical
If the mechanical stop pin has been deformed or stop axis 1 on page 70.
damaged, it must be replaced by a new one!
4 Also check that the stop pin is properly attached.

3 Maintenance
3.4.4 Inspection of air hoses (Foundry Prime)
General
The air hoses on Foundry Prime robots must be inspected for leakage every six
months.
Required equipment
Equipment, etc. Art. no.

Leak detection spray -
Pressure gauge -
Cut off valve -
Procedure
For this test it is recommended that the air supply to the robot has a pressure
gauge and a cut-off valve connected.
Action Note
1 Apply compressed air to the air connector on Recommended pressure:
robot base, and raise the pressure with the 0.2-0.3 bar
knob until the correct value is shown on the
pressure gauge.
B
xx0600003341
• A: Air Connection
• B: Pressure gauge
• C: Cut off valve
2 Close the cut off valve. It should take at least 5 seconds for the
pressure to reach 0 bar.
3 The time is < 5 seconds:
• If the answer is YES: Localize the
leakage by following the procedures
below.
• If the answer is NO: The system is OK.
Remove the leak testing equipment.
4 Pressurize by opening the cut off valve.
5 Spray suspected leak areas with leak detec-
tion spray.
Note
Bubbles indicate a leak.

3 Maintenance
Continued
Action Note
6 When the leak is localized: correct the leak.

3 Maintenance
3.4.5 Inspection of surface treatment (Foundry Prime)
3.4.5 Inspection of surface treatment (Foundry Prime)
Introduction to inspection of surface treatment

Damage to painted surfaces must be repaired as soon as possible to avoid
corrosion. All painted surfaces on the robot must be inspected.
Required equipment
Equipment, etc. Note

Touch up paint Foundry Prime 2, grey See Touch up paint for Foundry Prime robots in
partlistSpare Part lists on page 299.
Equipment Article number Note

Rust preventive 3HAC034903-001 Mercasol. Recommended
drying time is 24h.
Loctite 574 12340011-116
Brush
Inspection and repair of surface treatment

Use this procedure to inspect the surface treatment on Foundry Prime robots.
Action Information
1 Inspect all painted surfaces for damage.
2 Repair any damage as described in the in-
struction included in the spare part kit.

3 Maintenance
3.5.1 Replacing the SMB battery
3.5 General maintenance activities
Note
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 to be replaced.
For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For an SMB board with 2-pole battery contact, the typical lifetime of a new battery
is 36 months if the robot is powered off 2 days/week or 18 months if the robot is
powered off 16 h/day. The lifetime can be extended for longer production breaks
with a battery shutdown service routine. See Operating manual - IRC5 with
Location of battery pack

The battery pack is fit to the serial measurement unit, located inside the base. To
access the unit and battery pack, the rear cover plate shown in the figure below
must be removed.
xx0300000106
A Rear cover plate
Required equipment
Note
There are two variants of SMB units and batteries. One with 2-pole battery contact
and one with 3-pole battery contact. 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!

3 Maintenance
Continued

Battery pack For spare part number, see Spare Parts - Serial
measurement unit.
Standard toolkit The contents are defined in section Contents,
standard toolkit on page 295.
Other tools and procedures may be re- These procedures include references to the
quired. See references to these proced- tools required.
ures in the step-by-step instructions be-
low.
Replacement, battery pack

The procedure below details how to replace the battery pack in the serial
measurement unit.
Step Action Info/Illustration
1
xx0200000023
WARNING
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 54
2 Set the robot to the MOTORS OFF operating mode.

This way the robot does not need to be calibrated
after the battery change.
3 Remove the rear cover plate from the base. Shown in the figure Location
of battery pack on page 105.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
4 Loosen the battery terminals from the serial measur-

ing board and cut the clasps that keep the battery
pack in place.
5 Remove the old battery pack.
6 Fit a new battery pack with two clasps and connect
the terminals to the serial measuring board.

3 Maintenance
3.5.2 Cleaning the IRB 4400
DANGER
Turn off all:

to the robot, before entering the safeguarded space.
General
To secure high uptime it is important that the IRB 4400 is cleaned regularly. The
frequency of cleaning depends on the environment in which the product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 4400.
Note
Always verify the protection type of the robot before cleaning.
Oil spills
Oil spills from gearboxes
Use the following procedure if any oil spills are detected that can be suspected to
originate from a gearbox.
1 Inspect that the oil level in the suspected gearbox is according to the
recommendations, see Inspection activities on page 96.
2 Write down the oil level.
3 Inspect the oil level again 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 robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning.
• Never point the water jet at connectors, joints, sealings, or gaskets.
• Do not use compressed air to clean the robot.

3 Maintenance
Continued
• Never use solvents that are not approved by ABB to clean the robot.
• Do not spray from a distance closer than 0.4 m.
• Do not remove any covers or other protective devices before cleaning the
robot.
Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.
Protection Cleaning method
type
Vacuum Wipe with cloth Rinse with water High pressure water or
cleaner steam
Standard Yes Yes. With light Yes. It is highly re- No
cleaning deter- commended that
gent. the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
Foundry Yes Yes. With Yes. It is highly re- Yes i .
Prime cleaning deter- commended that It is highly recommended
gent approved the water contains that the water and steam
by ABB, spirit a rust-prevention contains rust preventive.
or isopropyl al- solution. If cleaning detergents are
cohol. used they must be ap-
See Approved proved by ABB for
cleaners and Foundry Prime robots.
detergents on See Approved cleaners
page 109. and detergents on
page 109.
i Perform according to section Cleaning with water and steam on page 108.
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/m 2 (7 bar) I
• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum flow: 20 liters/min I
I Typical tap water pressure and flow
Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be
cleaned using a steam cleaner or high pressure water cleaner. 2
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 2500 kN/m 2 (25 bar)
1 See Cleaning methods on page 108 for exceptions.
2 See Cleaning methods on page 108 for exceptions.

3 Maintenance
Continued
• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum water temperature: 80° C
Additional cleaning instructions for Foundry Prime robots

Washing detergents
• Only washing detergents approved by ABB shall be used.
• The washing detergent must be cleansed continuously.
• The washing detergent must contain rust inhibitor.
• The detergent pH value and concentration must be checked regularly.
• Allowed pH of the washing detergent is 9.0, if not stated otherwise.
• The user must follow the recommendations regarding detergent concentration
and pH value.
• No other additive than water is guaranteed without prior testing or agreement
with ABB. Other additives than water may have a harmful effect on the life
of the robot and its components.
• Recommendations given by the detergent manufacturer for the specific
detergent in question must be followed.
Note
If the pH value or the detergent concentration is varying from its original

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 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.
Washing without detergent

If the washing is performed without detergent, the water must contain rust inhibitor.
Cables
Movable cables need to be able to move freely:
• Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
3 Maintenance
Continued
• Clean the cables if they have a crusty surface, for example from dry release
agents.

3 Maintenance
3.6.1 Type of lubrication in gearboxes
3.6 Changing and inspecting oil
3.6.1 Type of lubrication in gearboxes
Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with lubrication.
Type and amount of oil in gearboxes

Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes available for registered users on myABB Business Portal,
www.abb.com/myABB.
Location of gearboxes
The figure shows the location of the gearboxes.
Equipment
Equipment Note
Oil dispenser Includes pump with outlet pipe.
Use the suggested dispenser or a similar one:
• Orion OriCan article number 22590
(pneumatic)
Nipple for quick connect fitting, with o-ring

3 Maintenance
3.6.2 Inspection of oil levels
Location of oil plugs, axes 2 and 3

The oil plug, filling for the gearbox unit, axes 2 and 3, is located as shown in the
figure below. The figure shows the location of the axis-2-side and is the same on
the opposite side.
xx0300000331
A Oil plug, filling
Location of oil plugs, axis 4

The axis 4 gearbox has one oil plug for draining and one oil plug for filling, located
as shown in the figure below.
xx0300000220
A Upper oil plug, filling

B Lower oil plug, draining

3 Maintenance
Continued
Location of oil plugs, axes 5 and 6 (all robot versions)

The wrist unit has two oil plugs for draining and one oil plug for filling, located as
shown in the figure below.
xx0300000223
A Oil plug, draining (2 pcs, the other oil plug not shown in figure)
B Oil plug, filling (also used for draining)
Required equipment

Standard toolkit 3HAC17594- Content is defined in section
1 Contents, standard toolkit on
page 295.
Other tools and procedures These procedures include ref-
may be required. See refer- erences to the tools required.
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.
1 Remove the oil plug, filling. Shown in the figure Location
of oil plugs, axes 2 and 3 on
page 112.
2 Measure the oil level from the oil plug hole. The oil must cover at least
Required oil level: 225 mm ± 25 mm. half of the lower arm bearing!
3 Fill or drain, if necessary. Where to find type of oil and

total amount is detailed in
Type and amount of oil in
4 Clean and refit the oil plug.

3 Maintenance
Continued
Inspection, oil level axis 4

The procedure below details how to inspect the oil level of the gearbox, axis 4.
WARNING
Changing and draining gearbox oil may require handling hot oil of up to 90 °C!
Make sure that protective gear like goggles and gloves are always worn during
this activity.
Also, be aware of possible pressure build up in gearbox! When opening the oil
plug, there may be pressure present in the gearbox, causing oil to spray from
the opening!
WARNING
When filling gearbox oil, do not mix different types of oil as this may cause severe
damage to the gearbox! Always use the type of oil specified by the manufacturer!
If the oils are mixed, the gearbox must be thoroughly rinsed! Contact ABB for
further instructions!
1 Move the upper arm to a horizontal position (calibra-
tion position).
2 Remove the upper oil plug, filling. Shown in the figure Location
of oil plugs, axis 4 on
page 112.
3 Required oil level: 4 mm to the edge of the oil plug
hole.
4 Fill with lubricating oil, if necessary. Where to find type of oil and
5 Refit the oil plug.
Inspection, oil level axis 5 and 6 (all robot versions)

The procedure below details how to inspect the oil level of wrist unit, axis 5 and 6
for all robot versions.
1 Move the robot to the calibration position.
2 Remove one of the oil plugs, draining at the rear of Shown in the figure Location
the wrist. of oil plugs, axes 5 and 6 (all
robot versions) on page 113.
3 Required oil level: on level with the edge of the oil
plug hole.
4 Fill with lubricating oil, if necessary Where to find type of oil and
5 Refit the oil plug.

3 Maintenance
3.6.3 Oil change, gearbox axis 4
Location of oil plugs

The axis 4 gearbox has one oil plug for draining and one oil plug for filling, located
xx0300000220
A Upper oil plug, filling

B Lower oil plug, draining
Required equipment

Lubricating oil - Information about the oil is found in
Technical reference manual - Lubrica-
tion in gearboxes.
See Type and amount of oil in gear-
boxes on page 111.
Standard toolkit 3HAC17594-1 Content is defined in section Contents,
Oil collecting vessel The capacity of the vessel must be
sufficient to take the complete amount
of oil.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.
CAUTION

3 Maintenance
Continued
Draining
The procedure below details how to drain the oil from the gearbox, axis 4.
Tip
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm
oil drains quicker than cold oil.
WARNING
this activity.
the opening!
1 Move the arms backward and the upper arm to a
nearly vertical position.
2 Remove the lower oil plug, draining and drain the oil Shown in the figure Location
into an oil collecting vessel. of oil plugs on page 115.
Capacity of the oil collecting
vessel is specified in Re-
quired equipment on
page 115.
Filling
The procedure below details how to refill the oil to the gearbox, axis 4.
Note
The specified amount of oil is based on the total volume of the gearbox. When
changing the oil, the amount of refilled oil may differ from the specified amount,
depending on how much oil has previously been drained from the gearbox.
WARNING

3 Maintenance
Continued
WARNING
When filling gearbox oil, do not overfill, since this could lead to internal
over-pressure inside the gearbox which in turn may:
• - damage seals and gaskets
• - completely press out seals and gaskets
• - prevent the manipulator from moving freely
1 Move the upper arm to a vertical position (rear end
upwards).
2 Remove the upper oil plug, filling. Shown in the figure Location
of oil plugs on page 115.
3 Fill the gearbox with lubricating oil. Where to find type of oil and
Correct oil level is specified
in section Inspection of oil
levels on page 112.

3 Maintenance
3.6.4 Oil change, gearbox axis 5 and 6 (all robot versions)

The wrist unit has two oil plugs for draining and one oil plug for filling, located as
xx0300000223
A Oil plug, draining (2 pcs, the other oil plug not shown in figure)
B Oil plug, filling (also used for draining)
Required equipment

Lubricating oil - Information about the oil is found in
Technical reference manual - Lubrica-
tion in gearboxes.
See Type and amount of oil in gear-
boxes on page 111.
Standard toolkit 3HAC17594-1 Content is defined in section Contents,
Oil collecting vessel The capacity of the vessel must be
sufficient to take the complete amount
of oil.
CAUTION

3 Maintenance
Continued
Draining oil
The procedure below details how to drain the oil from the wrist unit (axis 5 and 6).
Tip
WARNING
this activity.
the opening!
1 Move the upper arm to a horizontal position and turn
axis 4 to the calibration position.
2 Turn axis 4, 135°.
3 Remove the lower oil plug, draining at the rear of the Shown in the figure Location
wrist. of oil plugs on page 118.
Capacity of oil collecting
vessel is specified in Re-
quired equipment on
page 118.
4 Remove the other oil plug, draining.
5 Move axis 3 up -15° and let the oil run out for a
couple of minutes.
6 Turn axis 4 so that the oil plug, filling is facing Shown in the figure Location
downwards. of oil plugs on page 118.
7 Remove the oil plug, axis 5 to drain the oil.
8 Move axis 3 down to 0°.
9 Move axis 4 backwards and forwards a couple of
times to drain all the oil.
10 Clean and refit the both oil plugs, draining.
Filling oil
The procedure below details how to fill oil to the wrist unit (axis 5 and 6).
Note

3 Maintenance
Continued
WARNING
WARNING
axis 4 to calibration position.
2 Turn axis 4 so that the oil plug, filling is facing up- Shown in the figure Location
wards. of oil plugs on page 118.
3 Fill the wrist with lubricating oil through the oil plug Where to find type of oil and
hole, filling. total amount is detailed in
Fill in intervals so that the oil runs into the wrist. Type and amount of oil in
in section Inspection of oil
levels on page 112.
4 Clean and refit the oil plug, filling.

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

The wrist unit has one oil plug for draining the oil and one oil plug for filling, located
as shown in the figure below. The oil plug for filling is also used as an air inlet when
draining the oil.
xx0300000118
A Oil plug, draining

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

Lubricating oil 3HAC0860-1 Optimol Optigear BM 100
Volume: 800 ml
1 Standard tools on page 295.
Oil collecting vessel Capacity: 1000 ml
tions below.
CAUTION

3 Maintenance
Continued
Draining oil
The procedure below details how to drain the oil from the wrist unit (axis 5 and 6),
robot version IRB 4400/L10.
Tip
WARNING
this activity.
the opening!

2 Remove the oil plug, draining in the wrist. Shown in the figure Location
of oil plugs on page 121.
3 Turn axis 4 to a position where the oil plug, draining Shown in the figure Location
is faced downwards and drain the oil into an oil col- of oil plugs on page 121.
lecting vessel. Capacity of vessel is spe-
Also remove the oil plug, filling, in order to use it as cified in Required equipment
an air inlet. on page 121.
4 Turn axis 4 another 90° to allow the remaining oil to
be drained.
5 Clean and refit the oil plug, draining.
Filling oil
The procedure below details how to fill oil to the wrist unit (axis 5 and 6), robot
version IRB 4400/L10.
Note

3 Maintenance
Continued
WARNING
WARNING
Step Action Note/Illustration

2 Fill the wrist with lubricating oil through the oil plug Art. no. and amount are spe-
hole, filling. cified in Required equipment
on page 121.
in section Inspection, oil
level axis 5 and 6 (all robot
versions) on page 114.
3 Clean and refit the oil plug, filling.

3 Maintenance
3.7.1 Using the SIS system
3.7 Service Information System, M2000
3.7.1 Using the SIS system
General
This is a brief description of how to use the Service Information System, SIS for
M2000 robot systems. Details may be found in:
• Service Information System, SIS
• Defining the SIS input parameters
• Setting the SIS parameters
• Importing/exporting SIS data
• Reading the SIS output logs
The section is only valid for M2000 systems. For information regarding M2004
robot systems, see additional documentation, Operating manual - Service
Information System. Article number is specified in section References on page 10.
Basic procedure
Action Reference
1 Determine which of the system functions These are described in Description of
you require. Service Information System (SIS) on
page 125.
2 Define what values are adequate and suit- Recommendations on how to define these
able for your application in your production are given in SIS system parameters on
environment. page 128.
3 Enter these parameters in the system. How to do this is detailed in Setting the
SIS parameters on page 129.
4 Run the robot in normal operation.
5 Reset the counter if a repair is made, or if a The TPU displays for resetting any SIS
counter for any other reason is restarted. value are shown in Description of Service
Information System (SIS) on page 125.
6 When a time limit, set in the parameters, is How to access this is detailed in Reading
exceeded, a message may be read on the the SIS output logs on page 130.
Tech Pendant Unit (TPU).
7 If the log containing the message is to be These are described in Exporting the SIS
available from an external PC, or if the SIS data on page 131.
parameters are to be entered from an extern-
al PC, a set of software tools are available
to build such an application.

3 Maintenance
3.7.2 Description of Service Information System (SIS)
General
Service Information System (SIS) is a software function within the robot controller,
which simplifies maintenance of the robot system. It supervises the operating time
and mode of the robot, and alerts the operator when a maintenance activity is
scheduled.
Maintenance is scheduled by setting the system parameters of the type SIS
Parameters, see section Setting the SIS parameters on page 129. All system
parameters are described in User´s Guide - System Parameters.
Supervised functions
The following counters are available:
• Calendar time counter, a general alarm based on calendar time
• Operation time counter, a general alarm based on operational time
• Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox
service interval
service interval
service interval
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 the calendar time limit for maintenance is reached, a message is displayed
on the TPU. How to access this is detailed in section Reading the SIS output logs
on page 130.
The following information is available about the calendar time in the service routine.
Prev service Date when the counter was reset last time, i.e. after the last service.
Elapsed time Elapsed time since the counter was reset the last time.
Next service Date when next scheduled service is planned. This date is calcu-
lated using system parameters, as detailed in section Setting the
SIS parameters on page 129.
Remaining time Remaining time to next scheduled service date.

3 Maintenance
Continued
Operation time
This is a function within the control system that keeps track of the amount of time
the "MOTORS ON" signal is active, i.e. the amount of time the robot is in the
operating mode.
When the operation time limit for maintenance is reached, a message is displayed
on the TPU. How to access this is detailed in section Reading the SIS output logs
on page 130.
The following information is available about the operation time in the service routine.
Service interval The specified service interval until another service will be required.
This parameter was entered manually as detailed in section Setting
the SIS parameters on page 129.
Elapsed time Operation time since the service interval was set the last time.
Remaining time Remaining operation time until the time set in service interval has
expired.
Gearbox
Based on measurements, torque and RPM, for example, the system calculates an
expected service interval for each gearbox. When service is due, a message will
be shown on the TPU. How to access this is detailed in section Reading the SIS
output logs on page 130.
The following information is available about the joint service status in the service
routine.
Joint x OK Service status for axis x, i.e. the automatically calculated time
parameter has not been exceeded.
Joint x NOK The service interval for the axis in question has been reached.
Joint x N/A No service time parameter calculation available.
Applies to axes 4 and 5 (IRB 6600 and IRB 7600).
The following information is available for the axis service status in the service
routine.
Consumed time The consumed time as a percentage of the total amount of time.
Elapsed time Operation time for axis x since calculation began.
Remaining time Remaining operation time for axis x until the service time parameter
value has been reached.
Reset values
Counters may be reset at any time by running the service routine.
When resetting, the counter variables are reset. The variables are described in
section Exporting the SIS data on page 131!
Service interval exceeded

When the service time has been exceeded for the selection made, an error message
(Service interval exceeded!) is displayed.

3 Maintenance
Continued
No data available
When no data is available for the selection made, a message (No data available!)
is displayed when trying to display the data.

3 Maintenance
3.7.3 SIS system parameters
3.7.3 SIS system parameters
General
This section details the system parameters that may be set with estimated values.
The values can be defined by the operating organization as knowledge of the
robot's working conditions are accumulated.
Since the counters are to be used for purposes defined by the user, ABB cannot
give any recommendations regarding their definitions.
Operation time limit (service level)

The number of operation hours selected as service interval.
E.g. by setting the value "20,000", the SIS will save this as the nominal time for
activating the alarm, not counting the percentage described below.
Operation time warning

A percentage of the "Operation time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an
operation time "Reset" was made the last time.
Calendar time limit (service level)

The number of calendar years 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.
Gearbox warning
A percentage of the gearbox service interval as calculated by the system. E.g. by
setting the value "90", the SIS will alert the operator after 90% of the expected
service interval of each gearbox.
The robot system automatically detects and stores all required variables to calculate
the expected service interval (estimated remaining lifetime) of each gearbox. This
is done by extrapolating data from earlier operation into a function of time, using
a formula including:
• input and output torque
• gearbox spindle speed
• other variables

3 Maintenance
3.7.4 Setting the SIS parameters
3.7.4 Setting the SIS parameters
General
If the SIS system is to function properly, a number of parameters must be set. This
is detailed below.
Procedure M2000
This is an instruction of how to enter SIS parameters to the M2000 robot system.
Action Note
1 Open "System parameters" Detailed in the User's Guide.
using the TPU.
2 Go to "System paramet-
ers/Manipulator/types 2".
3 Select "0 SIS parameters"
and press "Enter".
4 Select the required system
The parameter list is dis-
played.
5 Select the required paramet- Available parameters are described in section SIS system
ers by stepping up and parameters on page 128.
down through the parameter
list.

3 Maintenance
3.7.5 Reading the SIS output logs
3.7.5 Reading the SIS output logs
General
Whenever a set condition has expired (e.g. max allowed operation time before
service), a message to this effect will be shown in the Operational log.
Access to logs
How to open a log and show its contents is detailed in the User's Guide, chapter
Service.
Available messages
The following messages may be shown:
Available in: SIS message in the Meaning:
log:
Calendar time Service Message The manually set calendar time limit has expired.
Service is due! How to set the limit is detailed in section Setting
X calendar days
since last service. Proceed with the required service as detailed in
chapter Repair on page 133 or chapter Maintenance
on page 91 depending on which type of service.
Calendar time Service Message X number of calendar days remain until the
X calendar days to manually set calendar time limit expires.
next service. How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
Operation time Service Message The manually set operation time limit has expired.
Service is due! How to set the limit is detailed in section Setting
X production hours
since last service. Proceed with the required service as detailed in
Operation time Service Message X number of operation hours remain until the
X production hours manually set operation time limit expires.
to next service. How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
Gearbox time Service Message The automatically calculated gearbox time limit
Gearbox x requires has expired.
service! Proceed with the required service as detailed in
Gearbox time Service Message X percent of gearbox hours remain until the auto-
X% of the service in- matically calculated gearbox time limit expires.
terval has expired for How to set the value determining when the mes-
gearbox x! sage is to be shown, is detailed in section Setting

3 Maintenance
3.7.6 Exporting the SIS data
3.7.6 Exporting the SIS data
General
This section describes the available variables for entering SIS parameters as well
as showing any values of exceeded time limits as detected by the SIS counters.
In a M2000 robot system, the values can be read on a PC using "Webware SDK".
How to access these variables and how to perform the actual programming
sequences are detailed in the robot system User's Guide.
Definitions
The table below defines the names and functions of all software variables available
for communication between the SIS and an external computer.
Signal Unit Counter type Function
sisRestartDate seconds Calendar time The date on which the supervision was star-
ted/reset last time.
sisCalendarT seconds Calendar time The number of hours since start/last reset.
sisTotRunT seconds Operation time Total number of operation hours since the
system was started. Corresponds to the oper-
ating time counter on the control cabinet.
sisRunT seconds Operation time 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.
sisL10h_1 hours Gearbox time Estimated life of gearbox axis 1
sisL10h_Time_1 seconds Gearbox time Operation time of gearbox axis 1
sisL10h_Time_6 hours Gearbox time Operation time of gearbox axis 6

4 Repair
4.1 Introduction
4 Repair
4.1 Introduction
Structure of this chapter

This chapter describes repair activities for the IRB 4400. Each procedure contains
the information required to perform the activity, for example spare parts numbers,
required special tools, and materials.
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Report replaced units
Note
When replacing a part on the IRB 4400, report to your local ABB the serial number,
the article number, and the revision of both the replaced unit and the replacement
unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Safety information
Make sure to read through the chapter Safety on page 19 before commencing any
service work.
Note
If the IRB 4400 is connected to power, always make sure that the IRB 4400 is
connected to protective earth and a residual current device (RCD) before starting
any repair work.

4 Repair
4.2.1 Mounting instructions for bearings
4.2 General procedures
General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment
Equipment, etc. Article number Note

Grease 3HAC042536-001 Shell Gadus S2
Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings

Attend to the following instructions while mounting a bearing on the robot.
Action Note
1 To avoid contamination, let a new bearing remain in its wrapping
until it is time for fitting.
2 Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
3 Bearing rings, inner rings, and roller elements must not be subjec-
ted to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.
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.
Action Note
1 Tension the bearing gradually until the recommended pre-tension is achieved.
Note
The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
2 Make sure the bearing is properly aligned as this will directly affect the durab-
ility of the bearing.
Greasing of bearings
Note
This instruction is not valid for solid oil bearings.

4 Repair
Continued
The bearings must be greased after assembly according to the following

instructions:
• The bearings must not be completely filled with grease. However, if space
is available beside the bearing fitting, the bearing may be totally filled with
grease when mounted, as excessive grease will be pressed out from the
bearing when the robot is started.
• During operation, the bearing should be filled to 70-80% of the available
volume.
• Ensure that grease is handled and stored properly to avoid contamination.
Grease the different types of bearings as 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.

4 Repair
4.2.2 Mounting instructions for sealings
General
This section describes how to mount different types of sealings.
Equipment
Consumable Article number Note

Grease 3HAC042536-001 Shell Gadus S2
Rotating sealings
The procedure below describes how to fit rotating sealings.
CAUTION
Please observe the following before commencing any assembly of sealings:

• Protect the sealing during transport and mounting, especially the main lip.
• Keep the sealing in its original wrappings or protect it well before actual
mounting.
• The fitting of sealings and gears must be carried out on clean workbenches.
• Use a protective sleeve for the main lip during mounting, when sliding over
threads, keyways or other sharp edges.
Action Note
1 Check the sealing to ensure that:
• The sealing is of the correct type.
• There is no damage on the main lip.
2 Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.
3 Lubricate the sealing with grease just before fitting. Article number is specified in
(Not too early - there is a risk of dirt and foreign Equipment on page 136.
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
A B C
xx2000000071
A Main lip
B Grease
C Dust lip

4 Repair
Continued
Action Note
4 Mount the sealing correctly with a mounting tool. A
Never hammer directly on the sealing as this may
result in leakage.
xx2000000072
A Gap
Flange sealings and static sealings

The following procedure describes how to fit flange sealings and static sealings.
Action
1 Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
2 Clean the surfaces properly in accordance with the recommendations of ABB.
3 Distribute the sealing compound evenly over the surface, preferably with a brush.
4 Tighten the screws evenly when fastening the flange joint.
O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.

4 Repair
Continued
Action Note
3 Check the o-ring grooves.
The grooves must be geometrically correct and
should be free of pores and contamination.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Check that the o-ring is not squashed outside
the o-ring groove.

4 Repair
4.2.3 Cut the paint or surface on the robot before replacing parts
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
When replacing parts on a robot with protection type Foundry Prime, it is important
to make sure that after the replacement, no surface without paint is exposed to the
aggressive working environment.
Required equipment
Equipment Spare parts Note

Sealing compound 3HAC026759-001 Sikaflex 521 FC. Color white.
Tooling pin Width 6-9 mm, made of wood.
Cleaning agent Ethanol
Knife
Lint free cloth
Rust preventive Mercasol
Brush
Touch up paint Foundry Prime / 3HAC035355-001 Grey
Foundry Prime 2 / Foundry Prime
3
Touch up paint Standard/Foundry 3HAC067974-001 Graphite White
Plus
Touch up paint Standard/Foundry 3HAC037052-001 ABB Orange
Plus
Removing
Action Description
1 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.
xx0900000121
2 Carefully grind the paint edge that is left on

the structure to a smooth surface.
Refitting
Action Description
1 Before the parts are refitted, clean the joint Use ethanol on a lint free cloth.
so that it is free from oil and grease.

4 Repair
Continued
Action Description
2 Place the tooling pin in hot water.
3 Seal all refitted joints with sealing compound.
xx0900000122
4 Use the tooling pin to even out the surface

of the sealing compound.
xx0900000125
5 For robots with protection type Foundry For robots with protection type Foundry
Prime Prime
Wait 10 minutes. Sikaflex 521FC skin dry time (10 minutes).
6 Use Touch up paint Foundry Prime, grey to 3HAC035355-001
paint the joint.
Note
Always read the instruction in the product

data sheet in the paint repair kit for Foundry
Prime.
7 Apply Mercasol on all screw heads and set

screws after tightening.

4 Repair
4.2.4 Performing a leak-down test
4.2.4 Performing a leak-down test
When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.
The gearbox must be drained of oil before performing the leak-down test.
Required equipment
Equipment, etc. Article number Note

Leak-down tester -
Leak detection spray -
Performing a leak-down test
Action Note
1 Finish the refitting procedure of the motor or gear in
question, but do not refill the gearbox with oil before
performing the leak-down test.
2 Remove the upper oil plug on the gear and replace
it with the leak-down tester.
Regulators, which are included in the leak-down test,
may be required.
3 Use caution, apply compressed air and raise the Correct value:
pressure with the knob until the correct value is 0.2-0.25 bar (20-25 kPa)
shown on the manometer.
CAUTION
The pressure must under no circumstance be higher

than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.
4 Disconnect the compressed air supply.

5 Wait for approximately 8-10 minutes and make sure If the compressed air is signific-
that no pressure loss occurs. antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.
6 If any pressure drop occurred, then localize the leak
as described in step 7.
If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.
7 Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.
8 When the leak has been localized, take the necessary
measures to correct the leak.

4 Repair
4.2.5 The brake release buttons may be jammed after service work
4.2.5 The brake release buttons may be jammed after service work
Description
The brake release unit has push-buttons for the brake release of each axis motor.
When service work is performed inside the SMB recess that includes removal and
refitting of the brake release unit, the brake release buttons may be jammed after
refitting.
DANGER
If the power is turned on while a brake release button is jammed in depressed

position, the affected motor brake is released. This may cause serious personal
injuries and damage to the robot.
Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
1 Make sure the power is turned off.
2 Remove the push-button guard, if necessary.
3 Verify that the push-buttons of the brake release unit are working by pressing them
down, one by one.
Make sure none of the buttons are jammed in the tube.
4 If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes.

4 Repair
4.3.1 Replacement of cable harness, axes 1-3
4.3 Complete robot
Location of cable harness, axes 1-3

The cable harness of axes 1-3 is located throughout the axis 1 of the robot as
shown in the figure below. Also see the following figure for the view X-X.
xx0300000111
A Rear cover plate

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

4 Repair
Continued
Location of cable harness, view X-X

The cable guides in the middle of axis 1 are located as shown in the figure below.
xx0300000110
C Connection box, motor 1. Connectors at motor 1: R3.MP1, R3.FB1.

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

Cable harness, axes 1-3 See Product IRB 4400 (all models)
manual, spare
parts - IRB 4400.
Gasket 3HAC4432-1 Between the motor and the
connection box, axes 1, 2
and 3.
Replace if damaged.
Standard toolkit 3HAC17594-1 Content is defined in sec-
tion Standard tools on
page 295.

4 Repair
Continued

Other tools and proced- These procedures include
ures may be required. references to the tools re-
See references to these quired.
procedures in the step-
by-step instructions be-
low.
Circuit diagram See chapter Circuit dia-
gram on page 301.
Calibration Pendulum In- General calibration inform-
struction ation is included in section
Calibration on page 263.
CAUTION
Removal, cabling axes 1-3

The procedure below details how to remove the cable harness from the axes 1-3.
1
DANGER
Turn off all:

Prime robots!)
2 Remove the rear cover plate. Shown in the figure Location

of cable harness, axes 1-3 on
page 143.
3 Remove the serial measurement unit. Removal detailed in section
Removal, serial measurement
unit on page 207.
4 Loosen the connectors R1.MP1, R2.FB1-3, R2.BU, Shown in the figure Location
R2.BU1-3. Also loosen the earth connections. of cable harness, axes 1-3 on
page 143.
5 Cut all the ties around bundle.
6 Remove the cable bracket inside the base.
7 Remove the cable guides and the protection plate in the Shown in the figure Location
middle of axis 1. of cable harness, view X-X on
page 144.
8 Remove the covers from the connections boxes for the
motors in axes 1-2-3.
9 Loosen all the connectors to the motors of axes 1-2-3. Shown in the figure Location
of cable harness, view X-X on
page 144.
10 Remove the connection boxes from the motors 1-2-3.

4 Repair
Continued
11 Feed the cabling up through the middle of axis 1 and
remove the complete cabling.
Tip! Gather the loose cabling and connectors into a
package with tape in order to protect the connectors and
make the cabling easier to handle.
Refitting, cabling axes 1-3

The procedure below details how to refit the cable harness to axes 1-3.
1
DANGER
Turn off all:

Prime robots!)
2 Feed the cable harness, axes 1-3 through the protection Part no. is specified in Re-
plate and down through the middle of axis 1. quired equipment on page 144
Tip
Gather the loose cabling and connectors into a package

with tape in order to protect the connectors and make
the cabling easier to handle.
3 Refit the connection boxes to the motors 1-2-3. Replace Part no. is specified in Re-
the gaskets if they are damaged. quired equipment on page 144
4 Reconnect the connectors in the motors 1-2-3. Shown in the figure Location
of cable harness, view X-X on
page 144
5 Refit the cable guide and the protection plate in the Shown in the figure Location
middle of axis 1. of cable harness, view X-X on
page 144
6 Secure the cabling with straps, according to foldout 3. See chapter Exploded views,
in Product manual, spare
parts - IRB 4400.
7 Refit the cable bracket inside the base.
8 Reposition the cabling inside the base according to fol- See chapter Exploded views,
dout 4. in Product manual, spare
parts - IRB 4400.
9 Reconnect all connectors at the base.
10 Refit the serial measurement unit. This is detailed in section Re-
fitting, serial measurement unit
on page 208.
11 Refit the rear cover plate. Shown in the figure Location
of cable harness, axes 1-3 on
page 143
12 Refit the covers of the connection boxes.

4 Repair
Continued
13 Recalibrate the robot! Calibration is detailed in a
separate calibration manual
enclosed with the calibration
tools.
General calibration information
is included in section Calibra-
tion on page 263.
14
DANGER
Make sure all safety requirements are met when perform-

ing the first test run. See Test run after installation,
maintenance, or repair on page 89.

4 Repair
Location of cable harness, axes 4-6

The cable harness of axes 4-6 is located throughout the robot as shown in the
figure below.
Also see the following figure for the view X-X.
xx0300000112
A Rear cover plate

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

4 Repair
Continued
Location of cable harness, view X-X

The cable guides in the middle of axis 1 are located as shown in the figure below.
xx0300000110
C Connection box, motor 1. Connectors at motor 1: R3.MP1, R3.FB1.

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

Cable harness, axes 4-6 See Product manu- IRB 4400 (all models)
al, spare parts - IRB
4400.
Gasket 3HAB3676-1 3 pcs
Between the motor and
the connection box.
Replace if damaged.
page 295.
ures may be required. See references to the tools re-
references to these pro- quired.
cedures in the step-by-

4 Repair
Continued

gram on page 301.
Calibration Pendulum In- Calibration is detailed in a
struction separate calibration
manual enclosed with the
calibration tools.
See References on
page 10.
CAUTION
Removal, cabling axes 4-6

The procedure below details how to remove the cable harness from the axes 4-6.
1
DANGER
Turn off all:

ing area.
2 Remove the cover ot the connection box for

motors 4-5-6.
3 Remove the rear cover plate. Shown in the figure Location of cable
harness, axes 4-6 on page 148
4 Remove the serial measurement unit. Detailed in section Removal, serial
measurement unit on page 207
5 Loosen the connectors R2.MP4-6, R2.FB4-6, Shown in the figure Location of cable
R2.BU4-6, R1.CP/CS. Also loosen the earth harness, axes 4-6 on page 148
connections.
6 Cut all the straps around the bundle.
7 Remove the cable bracket inside the base.
8 Remove the cable guides and the protection Shown in the figureLocation of cable har-
plate in the midle of axis 1. ness, view X-X on page 149

4 Repair
Continued
9 Loosen the cable brackets (A) between
gearboxes 2 and 3 and cut the strap around
them.
xx0300000113
10 Feed the cabling and the air hose, if any, up

through axis 1.
Tip
Gather the loose cabling and connectors into

a package with tape in order to protect the
connectors and make the cabling easier to
handle.
11 Loosen the cable bracket inside the lower Shown in the figure Location of cable
arm and undo the two screws. harness, axes 4-6 on page 148
12 Loosen the cable bracket at the upper arm. Shown in the figure Location of cable
harness, axes 4-6 on page 148
13 Loosen all the connectors to the motors at Shown in the figure Location of cable
the upper arm and customer connections, if harness, axes 4-6 on page 148
any.
14 Remove the connection box together with the
cabling.

4 Repair
Continued
Connection box, upper arm

The figure below shows the location of the motors, connectors and cabling in the
upper arm connection box.
xx0300000116
A Axis 4 motor
A1 Connector R3.MP4
A2 Connector R3.FB4
B Axis 5 motor
B1 Connector R3.MP5
B2 Connector R3.FB5
C Axis 6 motor
C1 Connector R3.MP6
C2 Connector R3.FB6
D Protection plate
E Cable strap, indoor
F cable strap, outdoor

4 Repair
Continued
Refitting, cabling axes 4-6

The procedure below details how to refit the cable harness to the axes 4-6.
1
DANGER
Turn off all:

to the robot, before entering the robot working
area.
2 Check the position of the three gaskets, located Part no. is specified in Required
between the motors and the connection box. Re- equipment on page 149.
place them if damaged.
3 Refit the connection box.
Make sure the gaskets are seated properly!
4 Reconnect all the connectors and reposition the Connectors and correct positioning
cabling inside the connection box using straps. are shown in the figure Connection
box, upper arm on page 152.
5 Refit the protection plate in the connection box. Shown in the figure Connection box,
upper arm on page 152.
6 Run the cabling through the lower arm.
7 Refit the cable bracket at the upper arm. Shown in the figure Location of cable
harness, axes 4-6 on page 148.
8 Refit the cable bracket inside the lower arm. Shown in the figure Location of cable
9 Feed the cabling through the protection plate and Shown in the figure Location of cable
down through the axis 1. harness, view X-X on page 149.
10 Refit the cable brackets (A) between the gearboxes
of axes 2 and 3 and strap the cabling.
xx0300000113
11 Refit the cable bracket inside the base.

12 Put straps around the bundle and position the See chapter Exploded views, in
cabling at the base according to foldout 4. Product manual, spare parts - IRB
4400.
13 Reconnect all the connectors at the base.

4 Repair
Continued
14 Refit the serial measurement unit. Detailed in Refitting, serial measure-
ment unit on page 208.
15 Refit the rear cover plate. Shown in the figure Location of cable
16 Refit the cover of the connection box in the upper
arm.
17 Recalibrate the robot! Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in section Calibration on
page 263.
18
DANGER
Make sure all safety requirements are met when

performing the first test run. See Test run after in-
stallation, maintenance, or repair on page 89.

4 Repair
4.3.3 Replacement of complete arm system
Location of complete arm system

The complete arm system includes the lower arm and the complete upper arm, as
xx0300000143
A Lower arm
B Upper arm
C Attachment screws and friction washers, lower arm
D Parallel arm
E V-ring between lower arm and gearbox axis 3
Required equipment

V-ring 3HAB3773-11 2 pcs.
On both sides of the lower
arm, in the frame.
Grease 3HAC042536- Used to grease sealings and
001 bearings.
Standard tools on page 295.

4 Repair
Continued

tions below.
Calibration Pendulum In- General calibration informa-
struction tion is included in section
CAUTION
Removal, complete arm system

The procedure below details how to remove the complete arm system from the
robot.
1
DANGER
Turn off all:

ing area.
2
CAUTION
The robot arm system weighs 245 kg.

accordingly!
3 Remove the tie rod. Detailed in section Replacement of tie rod

on page 189.
4 Remove the cabling down to axis 1. Detailed in section Replacement of com-
plete arm system on page 155.

4 Repair
Continued
5 Move the upper arm into a resting position
against the lower arm.
Lock the upper arm in this position with se-
curing slings around the lower and upper arm
(A), as shown in the figure to the right.
Note! If the arms are not properly secured,
the upper arm may move during the lift and
cause a drop of the complete arm system.
xx0300000142
Note! The figure shows the IRB 4400.

6 Unload the weight of the arm system with
lifting slings and a crane.
7 Remove the balancing device. Detailed in section Removal, balancing
device on page 199.
8 Remove the parallel arm. Detailed in section Replacement of paral-
lel arm / Replacement of bearing on
page 193.
9 Remove the attachment screws and friction Shown in the figure Location of complete
washers, lower arm. arm system on page 155.
10 Lift away the complete arm system.
Make sure the upper and lower arm are
properly secured to each other during the lift.
Refitting, complete arm system

The procedure below details how to refit the complete arm system to the robot.
1
DANGER
Turn off all:

• air pressure supply (do not turn off
for Foundry Prime robots!)
to the robot, before entering the robot
working area.

4 Repair
Continued
2
CAUTION

accordingly!
3 Check and grease both of the V-rings in the Part no. is specified in Required equipment
frame. Replace if damaged. on page 155
4 Lift the arm system into mounting position.
Make sure the arms are properly secured
to each other (A), as shown in the figure to
the right.
xx0300000142
5 Secure the arm system to the gearbox axis 10 pcs, M16x55. Tightening torque: 260 Nm.
2 with the attachment screws and friction Shown in the figure Location of complete
washers. arm system on page 155
Make sure both V-rings are seated properly!
6 Grease the bearing seating of the parallel
arm in the lower arm, to prevent clicking
during operation.
7 Refit the parallel arm. Detailed in section Refitting, parallel
arm/bearing on page 195
8 Refit the balancing device. Detailed in section Refitting of balancing
device on page 202
9 Move the upper arm to a horizontal position.
10 Refit the tie rod. Detailed in section Refitting, tie rod on
page 191
11 Refit the cabling to the upper arm. Detailed in section Refitting, cabling axes
4-6 on page 153

4 Repair
Continued
12 Recalibrate the robot! Calibration is detailed in a separate calibra-
tion manual enclosed with the calibration
tools.
General calibration information is included
in section Calibration on page 263.
13
DANGER
Make sure all safety requirements are met

when performing the first test run. See Test
run after installation, maintenance, or repair
on page 89.

4 Repair
4.4.1 Replacement of complete upper arm
4.4 Upper arm
Location of upper arm

The complete upper arm includes the wrist unit and is located as shown in the
figure below. (The figure shows the IRB 4400.)
xx0300000129
A Upper arm
B Connectors of motors, axes 4, 5 and 6
C Connection box, upper arm
D Calibration plate, axis 3
E VK cover
F KM nut
G Screw
H Bearing
I Sealing ring
J Shaft end

4 Repair
Continued
Required equipment

Upper arm, without wrist 3HAC17542-1 Foundry (also used for Stand-
and motors ard)
Color: ABB Orange.
3HAC050860- Foundry (also used for Stand-
001 ard)
Color: Graphite White
Sealing ring 3HAC7877-1
Taper roller bearing 3HAA2103-13
VK cover 3HAC12165-1
Shaft end 3HAC4744-1
Grease 3HAC042536- Used to grease the bearing.
001
Locking liquid Loctite 243
Dismounting tool 3HAC0163-1 Used to pull out the shaft.
Mounting tool 3HAB1463-1 Used to fit the inner ring of the
bearing.
Contains two separate parts.
De-air tool 3HAC8704-1 Used to evacuate air when re-
fitting VK-cover, if the cover
has no grooves for venting.
Other tools and proced- These procedures include ref-
ures may be required. See erences to the tools required.
references to these proced-
ures in the step-by-step in-
structions below.
Calibration Pendulum In- Art. no. is specified in section
struction Calibration on page 263.
CAUTION

4 Repair
Continued
Removal, upper arm

The procedure below how to remove the complete upper arm from the robot.
1
DANGER
Turn off all:

ing area.
2
CAUTION
The robot upper arm weighs 180 kg.

accordingly!
3 Move the upper arm to a horizontal position.

4 Secure the weight of the upper arm with the
lifting slings and a crane.
5 Remove the tie rod. Detailed in section Removal, tie rod on
page 190
6 Loosen the connectors of motors, axes 4, 5 Shown in the figure Location of upper arm
and 6. on page 160
7 Remove the connection box, upper arm from Shown in the figure Location of upper arm
the motors. on page 160
8 Remove the calibration plate, axis 3. Shown in the figure Location of upper arm
on page 160
9 Remove the VK covers on both sides of the Shown in the figure Location of upper arm
upper arm. on page 160
Be careful with the bearing beneath the cov-
er! Make a hole in the outer edge of the cover
and bend it away.
10 Undo the KM nuts. Shown in the figure Location of upper arm
on page 160
11 Remove the screws. Shown in the figure Location of upper arm
on page 160
12 Pull out the shaft with the dismounting tool. Art.no. is specified in Required equipment
Mark the shafts (left and right)! on page 161
13 Remove the sealings and bearings, if dam- Shown in the figure Location of upper arm
aged. on page 160
14 Remove the upper arm from the manipulator.

4 Repair
Continued
Refitting, upper arm

The procedure below details how to refit the complete upper arm to the robot.
1
DANGER
Turn off all:

ing area.
2
CAUTION
The robot upper arm weighs 180 kg.

accordingly!
3 Fit the sealings and the outer ring of the Shown in the figure Location of upper arm
bearings in the upper arm, if removed. on page 160.
The bearing must be completely filled with Part no. is specified in Required equip-
grease. ment on page 161.
4 Lower the upper arm into mounting position.
5 Refit both shaft ends. Shown in the figure Location of upper arm
on page 160.
Part no. is specified in Required equip-
ment on page 161.
6 Insert both screws. Shown in the figure Location of upper arm
on page 160.
2 pcs, tightening torque: 470 Nm.
7 If the bearing is removed, the inner ring of Art. no. is specified in Required equip-
the bearing is fitted as follows: ment on page 161.
• Fit the holding-on tool (part A of the
mounting tool) on the right side of the
upper arm (seen from behind).
• Fit the inner ring (C) of the bearing on
the left side of the upper arm, using
the press tool (part B of the mounting
tool).
• Remove the holding-on tool and fit the
inner ring also on that side. xx0300000130
• A: Holding-on tool
• B: Press tool
• C: Inner ring
8 Apply locking liquid on the threads of the KM Locking liquid specified in Required
nut. equipment on page 161
Shown in the figure Required equipment
on page 161.

4 Repair
Continued
9 Tighten the KM nut...
• on the left side, with torque 95 Nm in
order to center the upper arm
• on the right side first with 105 Nm.
Then unscrew the KM nut and re-
tighten it with torque 95 Nm.
Note! This procedure must be performed
within 10 minutes, before the Loctite begins
to harden.
10 Fit new VK covers. Part no. is specified in Required equip-
Note! If the covers have no grooves for ment on page 161.
venting, the air must be evacuated by using Shown in the figure Location of upper arm
the de-air tool (A). Also use a clamp as an on page 160.
aid in positioning the covers tilted, to avoid
overpressure.
xx0300000134
• A: De-air tool, used if the VK-cover

has no grooves for venting.
11 Refit the tie rod. Detailed in section Replacement of com-
plete upper arm on page 160.
12 Refit the calibration plate, axis 3. Shown in the figure Location of upper arm
on page 160.
13 Refit the connection box. Shown in the figure Location of upper arm
on page 160.
14 Reconnect the connectors to motors, axes Shown in the figure Location of upper arm
4, 5 and 6. on page 160.
15 Recalibrate the robot! Calibration is detailed in a separate calib-
ration manual enclosed with the calibra-
tion tools.
16
DANGER

on page 89.

4 Repair
4.4.2 Replacement of wrist unit
Location of wrist unit

The wrist unit is located in the upper arm as shown in the figure below. (The
illustration shows the IRB 4400.) Removal/refitting procedures differs depending
on robot version.
xx0300000150
A Wrist unit
B O-ring
C Sealing surface between wrist unit and upper arm tube
D Attachment screws and washers
Required equipment

Wrist unit 3HAB8271-1
(IRB 4400)
Wrist unit 3HAB9398-1 ABB Orange
(IRB 4400/L10) 3HAC050646- Graphite White
001

4 Repair
Continued

O-ring 21522012-541
(IRB 4400)
Grease 3HAC042536- Used to lubricate the o-ring
001 groove.
Flange sealing 12340011- Loctite 574
116
tions below.
struction Calibration on page 263 .
CAUTION
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 unit.
1
DANGER
Turn off all:

ing area.
2
CAUTION
The robot wrist unit weighs 48 kg.

accordingly!

4 Repair
Continued
3 Drain the oil from the wrist unit. Draining is detailed in sections Oil
change, gearbox axis 5 and 6 (all robot
versions) on page 118
4 Remove the attachment screws and washers
(A).
xx0300000148
Wrist unit on robot version IRB 4400.

5 Remove the wrist unit from the upper arm.
Refitting, wrist unit IRB 4400

The procedure below details how to refit the wrist unit to robot versions IRB 4400/60
and Foundry Prime.
Note
This component includes a complete unit comprising motors and gearboxes. It

is a replacement unit of complex design and should not normally be serviced
on-site. Instead it should be sent to ABB for service etc.
ABB recommends its customers carry out only the following servicing/repair
work on this unit.
1
DANGER
Turn off all:

ing area.
CAUTION
The robot wrist unit weighs 48 kg.

accordingly!
2 Lubricate the o-ring groove in order to posi- Part no. is specified in Required equip-
tion the o-ring. ment on page 165.
Fit the o-ring to the wrist. Shown in the figure Location of wrist unit
on page 165.

4 Repair
Continued
3 Apply flange sealing to the surface of the Specified in Required equipment on
wrist that will seal against the upper arm tube. page 165.
Sealing surface shown in the figure Loca-
tion of wrist unit on page 165.
4 Refit the wrist with attachment screws and
washers (A).
xx0300000148
• A: 8 pcs, M10x35. Tightening

torque: 41 Nm.
5 Fill the wrist unit with oil. Detailed in section Oil change, gearbox
axis 5 and 6 (all robot versions) on
page 118.
tion tools.
7
DANGER

on page 89.

4 Repair
4.4.3 Replacement of arm house unit, axis 4
Location of arm house unit

The arm house unit includes the axis 4 housing and the upper arm tube. It is located
xx0300000183
A Upper arm tube

B Axis 4 housing
Required equipment

Upper arm without wrist 3HAC17542-1 Foundry, also used for Stand-
and motors ard.
Color: ABB Orange.
3HAC050860- Foundry, also used for Stand-
001 ard.
Color: Graphite White
tions below.

4 Repair
Continued

struction Calibration on page 263.
CAUTION
Replacement, arm house unit

The procedure below details how to replace the arm house unit.
CAUTION
The complete arm house unit weighs 152 kg! All lifting equipment used must be
dimensioned accordingly!
1
DANGER
Turn off all:

ing area.
2 Remove the wrist unit. Detailed in section Replacement of arm

house unit, axis 4 on page 169.
3 Remove the motors for axes 4, 5 and 6. Detailed in section Removal of motor,
axes 4, 5 and 6 on page 232.
4 Remove the arm house unit. Detailed in section Replacement of arm
house unit, axis 4 on page 169.
5 Fit the new arm house unit. Part no. is specified in Required equip-
ment on page 169.
6 Refit the wrist unit. Detailed in section Replacement of wrist
unit on page 165.
7 Refit the motors for axes 4, 5 and 6. Detailed in sections
• Refitting of motor, axis 4 on
page 234
page 238
page 242
tion tools.

4 Repair
Continued
9
DANGER

on page 89.

4 Repair
4.4.4 Replacement of mechanical stop, axis 4
Location of mechanical stop

The mechanical stop of axis 4 is located in the upper arm as shown in the figure
below. (The figure shows the IRB 4400.)
xx0300000176
A Mechanical stop axis 4

B Damper axis 4
C Attachment screws, mechanical stop
Required equipment

Damper 3HAB3760-1
Flange sealing 12340011-116 Loctite 574
page 295.
tions below.

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

The procedure below details how to remove the axis 4 mechanical stop from the
robot.
1
DANGER
Turn off all:

Prime robots!)
2 Remove the mechanical stop by removing its attach- Shown in the figure Location
ment screws. of mechanical stop on
page 172.
3 Rotate axis 4 so that the damper is visible. Remove Shown in the figure Location
the damper. of mechanical stop on
page 172.

4 Repair
Continued
Refitting, mechanical stop

The procedure below details how to refit the axis 4 mechanical stop to the robot.
1
DANGER
Turn off all:

Prime robots!)
2 Fit the damper to the axis 4. Shown in the figure Location

of mechanical stop on
page 172.
Part no. is specified in Re-
quired equipment on
page 172.
3 Apply flange sealing to the stop. Art. no. is specified in Re-
quired equipment on
page 172.
4 Fit the mechanical stop to the axis 4 with its attach- Shown in the figure Location
ment screws. of mechanical stop on
page 172.
Part no. is specified in Re-
quired equipment on
page 172.
4 pcs, M8x16. Tightening
torque: 24 Nm.

4 Repair
4.4.5 Replacement of signal cabling, upper arm (option 042)
Location of signal cabling, upper arm

The signal cabling (option 042) runs along the upper arm as shown in the figure
below.
xx0300000192
A Wrist bracket
B Upper arm bracket
C Front and rear cable holders
D Plastic hose
Required equipment

Customer connection axis 3HAC8820-1 Includes signal/power cabling,
4 necessary brackets, holders
etc.
tions below.
CAUTION

4 Repair
Continued
Removal, signal cabling upper arm

The procedure below details how to remove the signal cabling from the upper arm.
1
DANGER
Turn off all:

area.
2 Remove the wrist bracket and the upper arm Shown in the figure Location of
bracket from the upper arm. signal cabling, upper arm on
page 175.
3 Remove the front and rear cable holders from Shown in the figure Location of
the tube shaft. signal cabling, upper arm on
page 175.
4 Disconnect the connectors at the rear of the
upper arm.
Refitting, signal cabling upper arm

The procedure below details how to refit the signal cabling to the upper arm.
1
DANGER
Turn off all:

area.
2 Fit transparent protection tape to the narrow

part of the tube shaft. Remove dirt and grease
from the surface first!
3 Move axis 4 to its calibration position (0°).

4 Repair
Continued
4 Refit the wrist bracket to the upper arm. Location of the bracket is shown
in the figure Location of signal
cabling, upper arm on page 175.
xx0300000193
• A: 2 pcs, M8x12.
5 Refit the upper arm bracket to the upper arm. Location of the bracket is shown
in the figure Location of signal
cabling, upper arm on page 175.
xx0300000194
• B: 3pcs, M8x12.
6 Slowly 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.
7 Complete the rotation.
Note! Do not tighten the rear cable holder, leave
it open!

4 Repair
Continued
8 First fit the front cable holder around the tube
shaft.
Run the black plastic hose through the foot of
the holder.
Fit the rear cable holder around the tube shaft
in the same way.
xx0300000197
• A: Plastic hose
• B: Cable holder
Also see the figure Location of
signal cabling, upper arm on
page 175.
9 Move axis 4 from one extreme limit to the other
and back again.
xx0100000003
Caution!
Check the cables during movement:
• the cables must not be fully extended!
• the cables and air hose must not touch
any moving parts of the arm!
• the fixing rings must always slide
smoothly with no excessive pulling!
10 Adjust the length of the cables by pushing and
pulling the cables through the inner holders,
which are still loose.
Note! When axis 4 is moving, no stretching of
the cables should be felt.
11 Tighten the holders by hand. Do not use tools.
12 Reconnect the connectors at the rear end of
the upper arm.
13 Connect the air hose.
14 Secure the cables and air hose together with
cable straps above the motors.
15
DANGER

performing the first test run. See Test run after
installation, maintenance, or repair on page 89.

4 Repair
4.4.6 Measuring the play, axis 5
General
After reassembly due to repair work or any other reason, the play in axis 5 and 6
must be checked to ensure the repetition accuracy of the robot positioning. The
procedure for axis 5 is detailed below.
Required equipment

Standard toolkit - Content is defined in sec-
page 295.
Measuring tool, play 3HAB1611-6
Measuring tool, play (IRB 4400/L10) 3HAB6337-1
Other tools and procedures may be required. These procedures include
See references to these procedures in the references to the tools re-
step-by-step instructions below. quired.

Loctite 574 12340011-116
Brush
Measurement, axis 5
The procedure below details how to measure the play of axis 5.
Note
The measuring tool and measuring values differ depending on robot version!
Action Information
1
DANGER
Turn off all:

working area.
2 Move the robot to calibration position and

turn the axis 4 90°.

4 Repair
Continued
Action Information
3 Fit the measuring tool, play to the turning Art. no. is specified in Required equip-
disk. ment on page 179.
4 Apply load F in one direction, as shown in
the figure to the right.
Note
Different load and distances for the differ-

ent robot versions, as specified to the right!
xx0300000186
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:
• B: 140 mm
• C: 85 mm
• F: 40 N
5 Remove the load and set the dial indicator
to zero.

4 Repair
Continued
Action Information
6 Apply load F in the opposite direction, as
shown in the figure to the right.
xx0300000187
Values for robot version IRB 4400:

• B: 100 mm
• C: 140 mm
• F: 200 N
• B: 140 mm
• C: 85 mm
• F: 40 N
7 Remove the load and measure the play by The maximum play allowed at the given
reading the dial indicator. distance from the center of axis 5 is, for
robot version
• IRB 4400: 0.20 mm
• IRB 4400/L10: 0.08 mm

4 Repair
General
After reassembly due to repair work or any other reason, the play in axis 5 and 6
must be checked to ensure the repetition accuracy of the robot positioning. The
procedure for axis 6 is detailed below.
Required equipment

Standard toolkit - Content is defined in sec-
page 295.
Measuring tool, play 3HAB1611-6
Measuring tool, play (IRB 4400/L10) 3HAB6337-1
Other tools and procedures may be required. These procedures include
See references to these procedures in the references to the tools re-
step-by-step instructions below. quired.

Loctite 574 12340011-116
Brush
Measurement, axis 6
The procedure below details how to measure the play in axis 6.
Note
The measuring tool and measuring values differ depending on robot version!
Action Information
1
DANGER
Turn off all:

• air pressure supply (do not turn
off for Foundry Prime robots!)
working area.
2 Fit the measuring tool, play to the turning Art. no. is specified in Required equipment
disk. on page 182.

4 Repair
Continued
Action Information
3 Attach a weight (m) at a distance (B) from
the wrist flange, in order to avoid the ef-
fects of play on axis 5.
Note
Different weight and distance for the dif-

ferent robot versions, as specified to the
right!
xx0300000188
Values for robot versions IRB 4400:

• B: 100 mm
• m: 20 kg
• B: 140 mm
• m: 10 kg
4 Apply load F in one direction.
Note
Different load and distances for the differ-

ent robot versions, as specified to the
right!
xx0300000189

• B: 100 mm
• C: 100 mm
• F: 100 N
• B: 100 mm
• C: 150 mm
• F: 40 N
5 Remove the load and set the dial indicat-
or to zero.

4 Repair
Continued
Action Information
6 Apply load F in the opposite direction,
as shown in the figure to the right.
xx0300000190

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

4 Repair
4.5.1 Replacement of lower arm
4.5 Lower arm
Location of lower arm

The lower arm is located as shown in the figure below. (The figure shows the IRB
4400.)
xx0300000141
A Lower arm

4 Repair
Continued
B Attachment screws and friction washers, lower arm

C Calibration plate, axis 2
D Damper
E Parallel arm
F V-ring between lower arm and gearbox axis 3
Required equipment

Lower arm 3HAC5955-1
(IRB 4400)
V-ring 3HAB3773-11 2 pcs
On both sides of the lower arm,
in the frame.
Grease 3HAC042536- Used to grease sealings and
001 bearings.
Other tools and proced- These procedures include ref-
ures may be required. erences to the tools required.
See references to these
low.
Calibration Pendulum In- General calibration information
struction is included in section Calibra-
tion on page 263.
CAUTION
Removal, lower arm

The procedure below details how to remove the lower arm from the robot.
1
DANGER
Turn off all:

working area.

4 Repair
Continued
2
CAUTION
The robot lower arm weighs 65 kg.

accordingly!
3 Remove the cabling down to axis 1. Detailed in section Replacement of

lower arm on page 185.
4 Remove the complete upper arm. Detailed in section Replacement of
lower arm on page 185.
5 Attach a crane to the lower arm and unload
the weight.
6 Remove the balancing device. Detailed in section Removal, balan-
cing device on page 199.
7 Remove the parallel arm. Detailed in section Replacement of
parallel arm / Replacement of bearing
on page 193.
8 Remove the attachment screws and friction Shown in the figure Location of lower
washers, lower arm. arm on page 185.
9 Remove the lower arm from the manipulator.
Refitting, lower arm

The procedure below deatails how to refit the lower arm to the robot.
1
DANGER
Turn off all:

Prime robots!)
2
CAUTION
The robot lower arm weighs 65 kg.

All lifting accessories used must be sized accord-
ingly!
3 Move the damper and the calibration plate from the Part no. is specified in Re-
old to the new lower arm. quired equipment on page186
4 Check and grease both V-rings in the frame. Replace Part no. is specified in Re-
if damaged. quired equipment on page186
5 Lift the lower arm and lower it into mounting position.
Make sure both V-rings stay seated properly!

4 Repair
Continued
6 Refit the lower arm to the gearbox axis 2 with attach- 10 pcs. M16x55. Tightening
ment screws and friction washers, lower arm. torque: 260 Nm.
Shown in the figure Location
of lower arm on page 185
7 Grease the bearing seating of the parallel arm in the
lower arm, to prevent clicking during operation.
8 Refit the parallel arm. Detailed in section Refitting,
parallel arm/bearing on
page 195
9 Refit the balancing device. Detailed in section Refitting
of balancing device on
page 202
10 Refit the upper arm. Detailed in section Refitting,
upper arm on page 163
11 Refit the cabling. Detailed in section Refitting,
cabling axes 4-6 on page 153
tools.
General calibration informa-
tion is included in section
13
DANGER

performing the first test run. See Test run after install-
ation, maintenance, or repair on page 89.

4 Repair
4.5.2 Replacement of tie rod
Location of tie rod

The tie rod is located as shown in the figure below. (Figure shows the IRB 4400.)
xx0300000117
A Tie rod
B Attachment screw
C Washer
D O-ring
E Sealing, outside
F Spherical roller bearing
G Sealing, inside
Required equipment

Washer 3HAB3704-1 Replace if damaged.

4 Repair
Continued

O-ring 3HAB3772-23
Sealing, outside 3HAC3297-1
Spherical roller bearing 3HAA2167-11
Sealing, inside 3HAC3990-11
Grease 3HAC042536- Used to lubricate the shaft
001 on the robot where the tie
rod is to be refitted.
Locking liquid Loctite 243
Puller tool 2 pcs
Used to pull out the tie rod
alternately at the upper and
lower end if the tie rod.
Press tool 3HAB1598-1 Used to press in the spheric-
al roller bearing.
Press tool, p-arm 3HAB1529-1 2 pcs.
Used to press on the tie rod
alternately at the upper and
lower end of the tie rod.
tions below.
CAUTION
Removal, tie rod

The procedure below details how to remove the tie rod from the robot.
1
DANGER
Turn off all:

Prime robots!)
2 Lock the upper arm in a horizontal position with help

of a crane or similar.

4 Repair
Continued
3 Remove the two attachment screws. Shown in the figure Location
of tie rod on page 189.
4 Remove the two washers, o-rings and sealings, out- Shown in the figure Location
side from the tie rod. of tie rod on page 189.
5 Insert a screw in each center, to be used as a sup-
port.
6 Use two puller tools to pull out the tie rod, one at the
upper and lower end.
Pull alternately at the upper end and at the lower end
with the puller tools!
7 Remove the bearings if they are to be replaced. The part no. for new bear-
ings is specified in section
Replacement of tie rod on
page 189.
Refitting, tie rod

The procedure below details how to refit the tie rod on to the robot.
1
DANGER
Turn off all:

Prime robots!)
2 If the bearings are to be replaced, fit new spherical Part/Art. no. is specified in
roller bearings and new sealings, inside to the tie Required equipment on
rod. page 189
Use the press tool.
3 Lift the tie rod to its mounting site. Make sure the tie
rod is refitted with the correct end up!
4 Grease the shaft on the robot and refit the tie rod on Art. no. is specified in Re-
to the robot using two press tolls for p-arm. quired equipment on page189
Press alternately at the upper and lower end with the
press tools!
5 Fit the sealings, outside to the tie rod. Part no. is specified in Re-
quired equipment on page189
6 Fit the o-rings to the tie rod. Part no. is specified in Re-
quired equipment on page189
7 Refit the washers and attachment screws using Shown in the figure Location
locking liquid. of tie rod on page 189
Locking liquid is specified in
Required equipment on
page 189

4 Repair
Continued
tools.
General calibration informa-
tion is included in section
9
DANGER


4 Repair
4.5.3 Replacement of parallel arm / Replacement of bearing
Location of parallel arm

The parallel arm is located on the robot, as shown in the figure below. (The figure
shows the IRB 4400.)
The bearing of the parallel arm is shown in the enlarged view.
xx0300000128
A Parallel arm
B Attachment screw
C Washer
D V-ring on parallel arm
E Bearing
F Sealing

4 Repair
Continued
Required equipment

V-ring sealing 3HAB3732-11
Groove ball bearing 3HAC10905-1
Sealing ring 3HAB3749-1
Grease 3HAC042536- Used to lubricate the bear-
001 ings and sealings.
Lifting tool 3HAB1412-1 Used to lift the parallel arm.
tions below.
CAUTION
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.
1
DANGER
Turn off all:

working area.
2
CAUTION
The parallel arm system weighs 118 kg.

accordingly!
3 Remove the tie rod. Detailed in Replacement of tie rod on

page 189.

4 Repair
Continued
4 Fit the lifting tool to the parallel arm. Art. no. is specified in Required equip-
Unload the arm with a crane. ment on page 194.
5 Loosen the attachment screws (A) so that

the cabling can be moved slightly.
xx0300000127
6 Remove the 10 attachment screws and

the washer that holds the parallel arm to
gearbox axis 3.
7 Lift away the parallel arm from the robot.
8 If they are to be replaced, remove the
bearing and sealings from the parallel
arm.
Refitting, parallel arm/bearing

The procedure below details how to refit the parallel arm on to the robot during
repair work. It also details how to fit a new bearing to the parallel arm as
replacement.
1
DANGER
Turn off all:

working area.
2
CAUTION
The parallel arm system weighs 118 kg.

All lifting accessories used must be
sized accordingly!
3 Fit the new V-ring to the parallel arm. Part no. is specified in Required equip-
ment on page 194

4 Repair
Continued
4 If the bearing is to be changed: Part no. is specified in Required equip-
• Heat the new groove ball bearing ment on page 194
to 170°C.
• Fit the bearing to the parallel arm.
If the old bearing is kept:
• Grease the bearing.
5 Fit the sealing ring to the bearing. Part no. is specified in Required equip-
ment on page 194
6 Refit the washer and the 10 attachment 10 pcs. M16x80, 12.9 quality UNBRAKO.
screws that hold the parallel arm to the Tightening torque: 260.
gearbox unit. Reused screws may be used, providing
they are lubricated as detailed in section
Screw Joints in the Product manual, ref-
erence information, before fitting.
7 Move the upper arm to a horizontal pos- Detailed in section Refitting, tie rod on
ition with a crane (if not already posi- page 191
tioned horizontal) and refit the tie rod.
8 Reposition the cabling and tighten the
cable attachment screws.
xx0300000127

tion tools.
10
DANGER
Make sure all safety requirements are

met when performing the first test run.
See Test run after installation, mainten-
ance, or repair on page 89.

4 Repair
4.6.1 Replacement of balancing device
4.6 Frame and base
Location of balancing device

The balancing device is located as shown in the figure below. (The figure shows
the IRB 4400.)
xx0300000100
A Balancing device
B Bracket
C Attachment screws, bracket (M12x50)
D Press out hole
E Front screws
F Fork
G End part of shaft

4 Repair
Continued
Required equipment

Balancing device See Product manu- Includes balancing device
IRB 4400 al, spare parts - IRB 3HAC3702-1
4400. Includes cylindrical roller
bearing 3HAC4334-2
Includes front screws
3HAC6456-1
Sealing ring with dust See Product manu-
lip al, spare parts - IRB
4400.
Grease 3HAC3537-1 Used to lubricate:
• the bearings at the
balancing device
brackets (min. 500
ml. in each bearing)
• the sealing at the bal-
ancing device brack-
ets
• the bearing at the
balancing device fork
Nipple Used to lubricate the bear-
ing at hte balancing device
fork.
The lubrication hole is di-
mensioned M10.
Standard toolkit 3HAC17594-1 The contents are defined in
section Standard tools on
page 295.
Securing front screws M10x40H
H= threaded to the head.
Used to unload the balan-
cing device before removal.
Press tool, bearing 3HAC5465-1 Used to fit the cylindrical
roller bearings and the seal-
ings into the brackets.
low.
CAUTION

4 Repair
Continued
Removal, balancing device

The procedure below details how to remove the balancing device.
1
WARNING
Do not under any circumstances, deal with

the balancing device in any other way than
that detailed in the product documentation!
For example, attempting to open the balan-
cing device is potentially lethal!
2
DANGER
Turn off all:

working area.
3
CAUTION
The balancing device weighs 50 kg.

accordingly!
4 Move the manipulator to the calibration pos-

ition, as shown in the figure to the right.
xx0300000088
• A: Approximately 2º

4 Repair
Continued
5 Remove the two securing screws (A), loc-
ated at the fork of the balancing device.
Also remove the plate (C) which secures
that the bushing (D) is held in position.
xx0300000089
The fork is shown in the figure Location of

balancing device on page 197.
6 Unload the balancing device by replacing
the two front screws (A) with two securing
front screws.
Unload the device level by fastening the
securing screws parallel with each other.
xx0300000095
Dimension specified in Required equip-

ment on page 198!
7 Check that the piston is unloaded by moving
it manually.

4 Repair
Continued
8 Remove the four attachment screws, bracket Shown in the figure Location of balancing
from the bracket at the right side of the bal- device on page 197!
ancing device (A), seen from above.
xx0300000098
9 Remove the bracket from the frame by Shown in the figure Location of balancing
pressing it out using a M10x30 screw in the device on page 197!
press out hole.
10 Remove the balancing device by pushing it
to the side.
Note!
The balancing device weighs 50 kg!
xx0300000099
11 If the balancing device is to be replaced with

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

4 Repair
Continued
Refitting of balancing device

The procedure below details how to refit the balancing device.
1
WARNING
Do not under any circumstances, deal with the

balancing device in any other way than that
detailed in the product documentation! For
example, attempting to open the balancing
device is potentially lethal!
2
DANGER
Turn off all:

area.
3
CAUTION
The balancing device weighs 50 kg.

All lifting accessories used must be sized ac-
cordingly!
4 Fit the cylindrical roller bearings and sealings The procedure is detailed in Fitting of
to the balancing device and brackets if cylindrical roller bearing on page 204
• the balancing device is a new spare Part no. is specified in Required equip-
part ment on page 198
• the old bearings/sealings are damaged.
5 Lift the balancing device to its mounting posi- If the balancing device is a new spare
tion. part, it must be unloaded as described
in Removal, balancing device on page 199
6 Fit the balancing device to the left bracket and Shown in the figure Location of balan-
put the fork into correct position. cing device on page 197
7 Refit the right bracket with attachment screws, 4 pcs: M12x50, tightening torque: 82 Nm
bracket . Shown in the figure Location of balan-
cing device on page 197
8 Refit the original protection screws in the press 2 pcs. MC6S M10x12 8.8 fzb.
out holes in both the brackets. Shown in the figure Location of balan-
cing device on page 197

4 Repair
Continued
9 Lubricate the bearing at the fork:
• Remove the two stop screws (B).
• Fill with grease through one of the lub-
rication holes, until excessive grease is
forced out through the second hole. Use
a nipple!
• Refit the two stop screws.
• Refit the plate with one screw M8x16
(C). This plate secures the bushing (D)
is held in its position.
xx0300000089
A: Securing screws (2 pcs)

B: Stop screws, M10 x 40 (2 pcs)
C: Plate and screw M8 x 16 (1 pc)
D: Bushing
10 Before restoring the balancing device, check The fork is shown in the figure Location
that: of balancing device on page 197
• the fork is in position
• the fork does not cover the lubrication
holes of the shaft!
11 Restore the balancing device by removing the
replacement front screws (A) and refitting the
original protection front screws.
xx0300000095
2 pcs: MC6S M10x12 8.8 fzb

12 Refit the fork to the shaft in the lower arm, by Shown in the figure above in Refitting of
refitting the two securing screws (A) at the fork balancing device on page 202
of the balancing device.
Make sure that the fork does not cover the
lubrication holes of the shaft!

4 Repair
Continued
13
DANGER

on page 89.
Fitting of cylindrical roller bearing

The procedure below details how to fit the cylindrical roller bearings onto the
balancing device shaft and into the frame brackets.
1 Fit the inner ring of the bearing onto both end parts of Shown in the figure Location
the balancing devices shaft. of balancing device on
page 197
2 Fit the outer ring of the bearing into both brackets with Art. no. is specified in Re-
a press toll, bearing. quired equipment on page 198
3 Fit the sealing ring with dust lip with the same, but Part no. is specified in Re-
turned, press tool, bearing. quired equipment on page 198
4 Lubricate the bearing and the sealing with grease. Art. no. and amount specified
in Required equipment on
page 198
5
DANGER
Make sure all safety requirements are met when perform-

ing the first test run. See Test run after installation,
maintenance, or repair on page 89.

4 Repair
4.6.2 Replacement of serial measurement unit
WARNING
See Hazards related to batteries on page 36.
Location of serial measurement unit

The serial measurement unit is located inside the base of the robot, behind the
rear cover, as shown in the figure below.
xx0300000106
A Rear cover plate
Different versions, serial measurement unit
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!

4 Repair
Continued
B F E B F E
(1) (2)
D D
C A C A
xx1300000355
1 and 2 Different versions of serial measurement unit

(2) New version of serial measurement unit (RMU 101)
A R2.SMB
B R2.FB4-6
C R2.FB1-3
D Fastening plate
E Battery pack
F Battery cable connector
Required equipment

Serial measurement unit See Product manual, spare parts - IRB 4400.
Fastening plate See Product manual, spare parts - IRB 4400.
Standard toolkit Content is defined in section Standard tools
on page 295.
Other tools and procedures may be re- These procedures include references to the
quired. See references to these procedures tools required.
in the step-by-step instructions below.
Circuit diagram See chapter Circuit diagram on page 301.
CAUTION

4 Repair
Continued
Removal, serial measurement unit

The procedure below details how to remove the serial measurement unit.
1
DANGER
Turn off all:

area.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the

unit read the safety information in section The
unit is sensitive to ESD on page 54.
3 Remove the rear cover plate from the base. Shown in the figure Location of
serial measurement unit on
CAUTION page 205.

4 Cut all the straps.

5 Unscrew the nuts that attaches the serial meas-
urement unit inside the base.
6 Remove the serial measurement unit.
7 Remove the connectors from the board. The connectors are shown in
Disconnect the battery cable by pressing down the figure Different versions,
the upper lip of the R2.G connector to release the serial measurement unit on
lock while pulling the connector upwards. page 205.
Removal of the battery cable
connector:
xx1700000993

4 Repair
Continued
Refitting, serial measurement unit

The procedure below details how to refit the complete serial measurement unit.
1
DANGER
Turn off all:

area.
2
The unit is sensitive to ESD. Before handling the

unit read the safety information in section The
unit is sensitive to ESD on page 54.
3 Refit the connectors to the serial measurement Art. no. is specified in Required
unit. equipment on page 206.
Make sure the lock on the battery cable connector The connectors are shown in
R2.G snaps into place during refitting. the figure Different versions,
page 205.
4 Refit the serial measurement unit inside the base
using nuts.
5 Strap the cables.
6 Refit the rear cover plate on the base. Shown in the figure Location of
page 205.
7 Recalibrate the robot! Calibration is detailed in a sep-
arate calibration manual en-
closed with the calibration
tools.
tion on page 263.

4 Repair
4.6.3 Replacement of the brake release board
Location of the brake release board

The brake release board is located in the base of the robot, as shown in the figure
xx0300000106
A Rear cover plate
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.
X8
X10
X9
xx1700000978
Required equipment
Equipment, etc. Spare part num- Article num- Note

ber ber
Brake release unit with 3HAC065019- DSQC1050
harness and bracket 001

4 Repair
Continued
Equipment, etc. Spare part num- Article num- Note

ber ber
tions below.
CAUTION
Removal, brake release board

The procedure below details how to remove the brake release board from the robot.
1
DANGER
Turn off all:

Prime robots!)
2

3 Secure the robot by moving:

• the lower arm to one of its end positions
• the upper arm to its end position.
4 Remove the rear cover plate. Shown in the figure Location
of the brake release board
CAUTION on page 209.

5 Take a picture or make notes of how the robot cabling

is positioned in regard to the brake release board.
6 Remove the connectors X8, X9 and X10 from the
brake release board.
X8
X10
X9
xx1700000978

4 Repair
Continued
7 Remove the brake release board by removing its at-
tachment screws.
Note
The guard plate will be dismantled when the screws

for brake release board are unscrewed.
Refitting of brake release board

The procedure below details how to refit the brake release board to the robot.
1
DANGER
Turn off all:

Prime robots!)
2

3 Refit the new brake release board with its attachment Maximum tightening torque:
screws. 5 Nm.
Note
Make sure that the guard plate is mounted when the

screws for brake release unit are reassembled.
4 Refit the connectors X8, X9 and X10 to the brake re- Shown in the figure Connect-
lease board. ors on the brake release
Be careful not to damage the sockets or pins. board on page 209.
Make sure the connector and its locking arms are
snapped down properly.
5 Verify that the robot cabling is positioned correctly,
according to previously taken picture/notes.
WARNING
Screened cables must not get in contact with the

brake release board after installation. Eliminate all
risks of contact between screened cables and the
brake release board.
6 Refit the rear cover plate to the base of the robot. Shown in the figure Location
of the brake release board
on page 209.

4 Repair
Continued
7
WARNING
Before continuing any service work, follow the safety

procedure in section The brake release buttons may
be jammed after service work on page 142!
8 Recalibrate the robot! Calibration is detailed in

section Calibration on
page 263.
9
DANGER


4 Repair
4.6.4 Replacement of mechanical stop pin, axis 1
Location of mechanical stop pin

The mechanical stop pin on axis 1 is located on the frame as shown in the figure
xx0300000182
A Mechanical stop pin, axis 1

B Set screw
Required equipment

tions below.
CAUTION

4 Repair
Continued
Replacement, mechanical stop pin

The procedure below details how to replace the mechanical stop pin on axis 1.
WARNING
replaced!
1
DANGER
Turn off all:

Prime robots!)
2 Remove the set screw. Shown in the figure in Loca-

tion of mechanical stop pin
on page 213.
3 Remove the old mechanical stop pin. Shown in the figure in Loca-
tion of mechanical stop pin
on page 213.
4 Refit the new mechanical stop with the set screw. Part no. is specified in Re-
quired equipment on
page 213.
M10x12

4 Repair
4.7.1 Replacement of motor, axis 1
4.7 Motors
Location of motor
The motor, axis 1, is located as shown in the figure below. (The figure shows the
IRB 4400.)
The motor and the drive gear constitute one unit.
xx0300000154
A Motor, axis 1
B Connection box with cover
C Attachment screws and washers
Required equipment

Motor unit, axis 1 3HAC5952-1 Elmo
(IRB 4400) Includes motor pinion.
3HAC021724-001 Color: ABB Orange
Yaskawa
Includes pinion
3HAC021724-003 Color: Graphite White
Yaskawa
Includes pinion
O-ring, motor 21520431-11

4 Repair
Continued

Gasket 3HAC4432-1 Between the motor and the
connection box.
Replace if damaged!
Power supply 24 VDC, 1.5 A
Used in order to release the
brakes.
Measuring tool 3HAB7887-1 or Choose one of the tools.
3HAB1408-1
low.
Circuit diagram See chapter Circuit diagram
on page 301.
Calibration Pendulum General calibration informa-
Instruction tion is included in section
CAUTION
Removal, motor axis 1

The procedure below details how to remove the motor, axis 1.
DANGER
If a shelf-mounted robot version is not flat mounted, the manipulator can contain
a living force!
Removing the motor from axis 1 may result in movement of the axis, because
the brake is released.
To avoid this, move the robot into normal calibration position or move axis 1 to
get the lowest location of the center of gravity for the upper arm.

4 Repair
Continued
Action Information
1
DANGER
Turn off all:

area.
2
CAUTION
Whenever parting/mating motor and gearbox,

the gears may be damaged if excessive force
is used!
3 Remove the cover of the connection box. Shown in the figure Location of mo-
tor on page 215.
4 Disconnect all the connectors in the motor.
5 Remove the connection box. Shown in the figure Location of mo-
tor on page 215.
6 Remove the attachment screws and washers Shown in the figure Location of mo-
of the motor. tor on page 215.
Note
Check the position of the motor label before

removing the motor! The motor must be
mounted back at the same position!
7 Remove the motor.
Refitting, motor axis 1

The procedure below details how to refit the motor, axis 1.
Action Information
1
DANGER
Turn off all:

area.
2
CAUTION

is used!

4 Repair
Continued
Action Information
3
Note
The motor units from Elmo and Yaskawa are

not compatible!
4 Check that the assembly surfaces are clean

from paint, lubricant etc.
Make sure that the motor and the gearbox are
not damaged or scratched.
5 Fit the o-ring to the new motor unit. Part no. is specified in Required
equipment on page 215
6 Release the brake of the motor by connecting Connect to connector R3.MP1
the 24 VDC power supply. • +24V: pin 7
• 0V: pin 8.
7 Apply flange sealing to the motor flange. Art. no. is specified in Required
8 Place the new motor in the gearbox.
Do not damage the pinion and the gear-wheel!
Note the position of the motor! The motor label
should be mounted in the same position as it
had before removal.
9 Fit the upper and lower screws (A, B) and
tighten until there is no space between the
motor flange and the gearbox.
There should be a big backlash between the
motor pinion and the gear.
xx0300000155
A: Lower screw
B: Upper screw
C: Pushing direction

4 Repair
Continued
Action Information
10 Adjustment detailed in section Ad-
Note justment of motors, axes 1-3 on
page 230
Adjust the motor before continuing the refitting
procedure!
11 Fit the other two attachment screws and wash- Total 4 pcs. M10x30.
ers. Tightening torque: 60 Nm.
12 Check the oil level. Fill with oil if necessary Detailed in section Inspection of oil
levels on page 112
13 Refit the connection box. Part no. is specified in Required
Replace the gaskets if they are damaged! equipment on page 215
14 Reconnect all the connectors.

15 Refit the cover of the connection box.
calibration manual enclosed with
the calibration tools.
page 263.
17
DANGER


4 Repair
Location of motor
IRB 4400.)
xx0300000159
A Motor, axis 2
B Connection box
C Attachment screws and washers
Required equipment

(IRB 4400) Includes pinion
Yaskawa
Includes pinion
Yaskawa
Includes pinion
O-ring 21520431-11

4 Repair
Continued

Power supply 24 VDC, 1,5 A
Used in order to release the
brakes.
Measuring tool 3HAB7887-1 Choose one of the two tools.
3HAB1408-1
low.
on page 301.
CAUTION

Action Information
1
DANGER
Turn off all:

Prime robots!)
xx0200000022
Secure the arm system before removing the motor!

The brake is located in the motor and is therefore
released when the motor is removed.
3
CAUTION
Whenever parting/mating motor and gearbox, the

gears may be damaged if excessive force is used!
4 Remove the cover of the connection box.

4 Repair
Continued
Action Information
6 Remove the connection box. Shown in the figure Location of
motor on page 220.
7
Note
Check the position of the motor label before removing

it. The motor must be mounted in the same position.
8 Remove the attachment screws and washers of the Shown in the figure Location of
motor. motor on page 220.
Note
Oil will start to run out when removing the motor!
9 Remove the motor.

Action Information
1
DANGER
Turn off all:

ing area.
2
CAUTION

is used!
3
Note
The motor units from Elmo and Yaskawa are

not compatible!

Make sure that the motor and the gearbox
are not damaged or scratched.
5 Mount the o-ring to the new motor unit. Part no. is specified in Required equip-
ment on page 220
• 0V: pin 8

4 Repair
Continued
Action Information
7 Apply flange sealing to the motor flange. Art. no. is specified in Required equip-
ment on page 220
Do not damage the pinion or the gear wheel!
Note
Check the position of the motor! The motor

label should be mounted in the same position
as it had before the removal.

xx0300000160
A: Upper screw
B: Lower screw
10 Adjustment is detailed in section Adjust-
Note ment of motors, axes 1-3 on page 230
Adjust the motor before continuing the refit-

ting procedure!
11 Fit the other two attachment screws and Shown in the figure Location of motor
washers. on page 220
2 pcs: M10x70
2 pcs: M10x30
Tightening torque: 60 Nm
12 Refill with oil. Where to find type of oil and total
amount is detailed in Type and amount
of oil in gearboxes on page 111.
13 Refit the connection box. Shown in the figure Location of motor
on page 220
14 Reconnect the connectors.
16 Recalibrate the robot! Calibration is detailed in a separate cal-
ibration manual enclosed with the calib-
ration tools.
General calibration information is in-
cluded in section Calibration on
page 263.

4 Repair
Continued
Action Information
17
DANGER

on page 89.

4 Repair
Location of motor
IRB 4400.)
xx0300000163
A Motor, axis 3
B Connection box
C Attachment screws and washers, motor
Required equipment

Yaskawa
Includes pinion
Yaskawa
Includes pinion
O-ring 21520431-11

4 Repair
Continued

page 295.
To be used for releasing
the brakes.
Measuring tool 3HAB7887-1 Choose one of the two
3HAB1408-1 tools.
tions below.
gram on page 301.
Calibration Pendulum In- General calibration inform-
struction ation is included in section
CAUTION

Action Information
1
DANGER
Turn off all:

Prime robots!)
2
DANGER
Secure the upper arm system before removing the

motor from axis 3! The brake is located in the motor
and is therefore released when the motor is removed.
3
CAUTION
Whenever parting/mating motor and gearbox, the gears

may be damaged if excessive force is used!
4 Remove the cover from the connection box.

4 Repair
Continued
Action Information
6 Remove the connection box from the motor. Shown in the figure Location of
motor on page 225.
7
Note
Check the position of the motor label before removing

it! The motor must be mounted in the same position.
8 Remove the attachment screws and washers, motor. Shown in the figure Location of
motor on page 225.
Note
Oil will start to run out when removing the motor!
9 Remove the motor.
Refitting motor axis 3

Action Information
1
DANGER
Turn off all:

ing area.
2
CAUTION

is used!
3
Note
The motor units from ELMO and YASKAWA

are not compatible!

5 Fit the o-ring to the new motor unit. Part no. is specified in Required equip-
ment on page 225
6 Release the brake of the motor by connecting Connect to connectorR3.MP3
• 0V: pin 8
7 Apply flange sealing to the motor flange. Art. no. is specified in Required equipment
on page 225

4 Repair
Continued
Action Information
Do not damage the pinion and the gear Note
wheel!
Check the position of the motor! The motor
label should be mounted in the same pos-
ition as it had before the removal.

xx0300000160
Motor axis 2, is shown in the figure!

A: Upper screw
B: Lower screw
10 Adjustment is detailed in section Adjust-
Note ment of motors, axes 1-3 on page 230
Adjust the motor before continuing the refit-

ting procedure!
11 Fit the other two attachment screws and Shown in figure Location of motor on
washers, motor. page 225
M10x70
M10x30
Tightening torque: 60 Nm
12 Refill with oil. Where to find type of oil and total amount
is detailed in Type and amount of oil in
13 Refit the connection box. Shown in the figure Location of motor on
page 225
14 Reconnect the connectors.
ration manual enclosed with the calibration
tools.

4 Repair
Continued
Action Information
17
DANGER

on page 89.

4 Repair
4.7.4 Adjustment of motors, axes 1-3
General
This section details how to adjust the motors during refitting. It applies to the motors
in axes 1, 2 and 3 and is a complement to the refitting instructions found in sections
• Replacement of motor, axis 1 on page 215
• Replacement of motor, axis 2 on page 220
• Replacement of motor, axis 3 on page 225.
Required equipment

Standard toolkit 3HAC17594-1 Content is defined in section Standard
tools on page 295.
Measuring tool Either Choose one of the tools. They are all
3HAB7887-1 or compatible with the motor.
3HAB1408-1
For releasing the brakes.
Circuit diagram See chapter Circuit diagram on
page 301.
CAUTION
Adjustment
The procedure below details how to adjust the motors during refitting.
Action Information
1 Lock the motor brake before mounting the
adjustment tool.
2 Fit the measuring tool to the motor axis. Art. no. is specified in Required equip-
ment on page 230.

4 Repair
Continued
Action Information
3 Release the brake of the current motor by Axis 1 motor: connect to connector
connecting the 24VDC supply. R3.MP1
• +24V: pin 7
• 0V: pin 8.
Axis 2 motor: connect to connector
R3.MP2
• +24V: pin 7
• 0V: pin 8.
Axis 3 motor: connect to connector
R3.MP3
• +24V: pin 7
• 0V: pin 8.
4 Rotate the motor shaft with the measuring
tool. Measure the torque in both directions
with a spring balance.
A normal torque is 0.6-0.8 Nm (=6-8 N on ra-
dius 100 mm). Torques higher than 0.8 Nm
are not allowed, as they will reduce the life-
time of the motor and gear.
5 Loosen the lower and upper screws until the
motor can be moved sideways by hand. Note
The brake must be released in the mo-

tor.
6 Push the motor with one hand against the

gear and tighten the two screws with the
other hand.
7 Measure the torque with the motor shaft in 1) The brake disc is mounted on the
different positions. The torque should be max. motor shaft with a type of splined
0.1 Nm (on radius 50 mm) more than meas- coupling. Between the splines there is
ured before. a narrow backlash.
If the torque is more,
• slightly loosen the screws a little and Note
carefully knock the motor in the oppos-
ite direction There should always be a backlash, but
• then measure the torque again. it should be as minimal as possible.
Check that the backlash is very limited, by
moving the tool back and forward in small
movements.
When turning the motor shaft, a tick-tack
sound can be heard from the brake disc 1) .
This should not be mixed up with the back-
lash. The difficult part is to find the motor
position where the torque just starts to in-
crease.
8 Remove the measuring tool.
9 Disconnect the brake release voltage.
10 Continue refitting the motor. Refitting, motor axis 1 on page 217
Refitting, motor axis 2 on page 222
Refitting motor axis 3 on page 227

4 Repair
4.7.5 Removal of motor, axes 4, 5 and 6
Location of motors
The motors, axes 4, 5 and 6, are located as shown in the figure below. (The figure
The motor and the drive gear of each axis constitute one unit.
xx0300000164
A Motor unit, axis 4

B Motor unit, axis 5
C Motor unit, axis 6
D Attachment screws and washers, motor
E Connection box
Required equipment

Standard toolkit 3HAC17594-1 Content is defined in section Stand-
ard tools on page 295.
Circuit diagram See chapter Circuit diagram on
page 301.

4 Repair
Continued
CAUTION
Removal, motor axes 4, 5 and 6

The procedure below details how to remove the motors of axes 4, 5 and 6.
Action Information
1
DANGER
Turn off all:

Prime robots!)
2
DANGER
Secure the arm system before removing any motor!

The brake is located in the motor and is therefore re-
leased when the motor is removed!
3
CAUTION
Whenever parting/mating motor and gearbox, the gears

may be damaged if excessive force is used!
4 Drain the oil from the gearbox. Draining is detailed in sections:

• Oil change, gearbox axis
4 on page 115.
5 and 6 (all robot ver-
sions) on page 118
5 Remove the cover of the connection box.
6 Disconnect all the connectors in the connection box.
7 Remove the connection box. Shown in the figure Location of
motors on page 232.
8
Note
Check the position of the motor before removing it.

The motor must be mounted back at the same position.
9 Remove the attachment screws and washers, motor. Shown in the figure Location of
motors on page 232.
10 Remove the motor.

4 Repair
4.7.6 Refitting of motor, axis 4
Location of motor
xx0300000164

C Motor unit axis 6
E Connection box
Required equipment

(IRB 4400) Includes pinion.
Yaskawa
Includes pinion
Yaskawa
Includes pinion
4 Repair
Continued

Motor unit, axis 4 3HAC021962-001 Color: ABB Orange
(IRB 4400/L10) Yaskawa
Includes pinion
Yaskawa
Includes pinion
O-ring 21522012-426
Between the motors and
the connection box.
Replace if damaged.
Standard toolkit 3HAC17594-1 Content is defined in
section Standard tools
on page 295.
Measuring tool 3HAB1409-1
Power supply 24VDC, 1.5A
Used to release the
brake of the motor.
Other tools and procedures These procedures in-
may be required. See refer- clude references to the
ences to these procedures tools required.
tions below.
gram on page 301.
Calibration Pendulum In- Art. no. is specified in
struction section Calibration on
page 263 manual.
CAUTION

Action Information
1
DANGER
Turn off all:

area.

4 Repair
Continued
Action Information
2
CAUTION

is used!
3
Note
The motor unit from ELMO and YASKAWA

are not compatible!

5 Fit the o-ring to the new motor unit. Part no. is specified in Required equip-
ment on page 234.
6 Fit the measuring tool to the rear of the motor. Art. no. is specified in Required equip-
ment on page 234.
• 0V: pin 8.
8 Place the new motor unit in the gearbox.
Do not damage the pinion or the gear wheel.
9 Find the position with the least play by turning
the motor shaft 10 revolutions, noting
changes in play as you turn the motor.
10 Push the motor in a radial direction so that
the play is minimal within one motor revolu-
tion without the gear "chewing".
11 Refit the motor with its attachment screws Shown in the figure Location of motor
and washers, motor. on page 234.
4 pcs, M6x25. Tightening torque: 15 Nm.
12 Refill with oil, if drained. Detailed in section Oil change, gearbox
axis 4 on page 115.
13 Check the position of the three gaskets, loc- Part no. is specified in Required equip-
ated between the motors and the connection ment on page 234.
box. Replace them if damaged.
14 Refit the connection box. Shown in the figure Location of motor
Make sure the gaskets are seated properly! on page 234.
16 Refit the cover to the connection box.
calibration tools.
page 263.

4 Repair
Continued
Action Information
18
DANGER

on page 89.

4 Repair
Location of motor
The motors, axes 4, 5 and 6 are located as shown in the figure below. (The figure
The motor and drive gear of each axis constitutes one unit.
xx0300000164

E Connection box

4 Repair
Continued
Required equipment

Yaskawa
Includes pinion
Yaskawa
Includes pinion
Includes pinion
Yaskawa
Includes pinion
O-ring 21522012-426
Between the motor and the
connection box.
Replace if damaged.
2 pcs, used to release the
brakes in the motors for axes
4 and 5.
low.
on page 301.
Calibration Pendulum Art. no. is specified in section
Instruction Calibration on page 263.
CAUTION

4 Repair
Continued

The procedure below details how to refit the axis 5 motor.
Action Information
1
DANGER
Turn off all:

area.
2
CAUTION

3
Note
The motor units from ELMO and YASKAWA are

not compatible!
4 Check that the assembly surfaces are clean from

paint, lubricant etc.
Make sure that the motor and the gearbox are not
damaged or scratched.
5 Fit the o-ring into the new motor. Part no. is specified in Required
equipment on page 239.
6 Fit the measuring tool to the rear of the motor. Art. no. is specified in Required
7 Release the brakes in the motors for axes 4 and Connect to connector
5, by connecting the 24 VDC power supply. R3.MP4/MP5
• +24V: pin 7
• 0V: pin 8.
Do not damage the pinion or the gear wheel.
9 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 is the smallest.
10 Turn the motor for axis 5 one full revolution at a
time, five revolutions in all. Find the smallest play
within this range.
11 Push the motor in a radial direction so that the
play is minimal within one motor revolution without
the gear "chewing".
12 Refit the motor with its attachment screws and Shown in the figure Location of
washers, motor. motor on page 238.
4 pcs, M6x25. Tightening torque:
15 Nm.

4 Repair
Continued
Action Information
13 Refill with oil, if drained. Detailed in section:
• Oil change, gearbox axis 5
and 6 (all robot versions) on
page 118.
between the motors and the connection box. Re- equipment on page 239.
place them if damaged.
15 Refit the connection box. Shown in the figure Location of
Make sure the gaskets are seated properly! motor on page 238.

17 Refit the cover on the connection box.
18 Recalibrate the robot! Calibration is detailed in a separ-
ate calibration manual enclosed
with the calibration tools.
page 263.
19
DANGER


4 Repair
Location of motor
xx0300000164

E Connection box
Required equipment

Motor unit, axis 6 3HAC021728-001 Yaskawa

4 Repair
Continued

Includes pinion
Yaskawa
Includes pinion
O-ring 21522012-426
Between the motors and
the connection box.
Replace if damaged.
page 295.
3 pcs, used to release the
brakes in the motors for
axes 4, 5 and 6.
ures may be required. See references to the tools re-
references to these proced- quired.
ures in the step-by-step
instructions below.
gram on page 301.
Calibration Pendulum In- Art. no. is specified in
struction section Calibration on
page 263.
CAUTION

The procedure below details how to refit the axis 6 motor.
Action Information
1
DANGER
Turn off all:

Prime robots!)

4 Repair
Continued
Action Information
2
CAUTION

3
Note
The motor units from ELMO and YASKAWA are not

compatible!
4 Check that the assembly surfaces are clean from

paint, lubricant etc.
Make sure that the motor and the gearbox are not
damaged or scratched.
5 Fit the o-ring to the new motor unit. Part no. is specified in Required
6 Fit the measuring tool at the rear of the motor. Art. no. is specified in Required
7 Release the brakes in the motors for axes 4, 5 and Connect to connector
6, by connecting the 24 VDC power supply. R3.MP4/MP5/MP6
• +24V: pin 7
• 0V: pin 8.
Do not damage the pinion or the gear wheel!
9 Find the position of least play by turning the outgoing
shaft for axis 4 in intervals of 90°, one revolution in
all, to locate the area where the play for the axis 6
motor is the smallest.
10 Turn the motor for axis 5 one full revolution at a time,
five revolutions in all. Find the least play for axis 6
within this range.
11 Turn the motor for axis 6 one full revolutipon at a
time, three turns in all. Find the least play for axis 6
within this range.
12 Push the motor in a radial direction so that the play
is minimal within one motor revolution without the
gear "chewing".
13 Refit the motor with its attachment screws and Shown in the figure Location of
washers, motor. motor on page 242.
4 pcs, M6 x 25. Tightening
torque: 15 Nm.
14 Refill with oil, if drained. Detailed in section
5 and 6 (all robot ver-
sions) on page 118.
between the motors and the connection box. Replace equipment on page 242.
them if damaged.
16 Refit the connection box. Shown in the figure Location of
Make sure the gaskets are seated properly! motor on page 242.

4 Repair
Continued
Action Information
18 Refit the cover on the connection box.
19 Recalibrate the robot! Calibration is detailed in a sep-
arate calibration manual en-
closed with the calibration tools.
tion on page 263.
20
DANGER


4 Repair
4.8.1 Replacement of gearbox unit, axes 1-2-3
4.8 Gearboxes
General
The gearboxes of axes 1-2-3 are handled as one complete unit. Except for the
gearboxes, the spare part also includes motor units and lubricating oil for the axes
1, 2 and 3.
Location of gearbox unit

The gearbox unit, axes 1-2-3, is shown in the figure below. (The figure shows the
IRB 4400.)
xx0300000174
A Gearbox unit axes 1-3, spare part

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

4 Repair
Continued
Required equipment

Gearbox unit, axes 1-3 3HAC061747- ABB Orange
(IRB 4400) 005 Does not include motors and
lubricating oil.
3HAC061747- Graphite White
004 Does not include motors and
lubricating oil.
Sealing 3HAC5479-2 Replace if damaged!
Lifting slings with hoisting Lifting capacity: 500 kg.
block
tions below.
Calibration Pendulum in- General calibration information
struction is included in section Calibra-
tion on page 263.
CAUTION
Removal, gearbox unit

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

working area.
2
CAUTION

sized accordingly!

4 Repair
Continued
3
CAUTION
The robot base weighs 130 kg.

sized accordingly!
4 Remove the cable harness and serial Detailed in sections Replacement of cable
measuring board. harness, axes 1-3 on page 143, and Re-
placement of serial measurement unit on
page 205.
5 Remove the tie rod. Detailed in section Replacement of tie rod
on page 189.
6 Remove the parallel arm. Detailed in section Replacement of paral-
lel arm / Replacement of bearing on
page 193.
7 Remove the complete arm system. Detailed in section Replacement of com-
plete arm system on page 155.
8 Unfasten the robot from the foundation.
9 Fit and secure straps (A) around the rear This figure shows the IRB 4400.
part of the gearbox unit, as shown in the
figure to the right. Attach the straps to
lifting slings with a hoisting block.
Fit and secure hooks to the lifting lugs
(B).
Use the same crane for both attachment
points.
xx0300000172
10 Lift the gearbox unit together with the

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

4 Repair
Continued
11 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.
xx0300000173
• B: Approximately 200 mm (IRB

4400 all models)
12 Remove the bottom plate from the base. Shown in the figure Refitting, complete
arm system on page 157.
13 Move the lifting straps to the base and
unload its weight.
14 Remove the attachment screws and Shown in the figure Refitting, cabling axes
washers, gearbox unit. 1-3 on page 146.
15 Remove the base from the gearbox unit.
16 Remove the sealing from the gearbox
unit.
Refitting, gearbox unit

The procedure below details how to refit the gearbox unit, including motors, to the
robot.
1
DANGER
Turn off all:

working area.

4 Repair
Continued

2
CAUTION
The robot base weighs 130 kg.

accordingly!
3
CAUTION

accordingly!
4 Place the new gearbox unit on a level sur-

face and support it at position A, according
to the figure on the right.
Make sure the unit is stable and rests secur-
ily on the surface, including the weight of
the base that is to be refitted.
xx0300000173
Part no. is specified in Required

B: Approximately 200mm (IRB 4400
models)
5 Refit the sealing to the gearbox unit. Shown in figure Location of gearbox
Replace it if damaged. unit on page 246
Part no. is specified in Required
6 Raise the base and fit it to the gearbox unit.
Align the hole pattern of the base to the
gearboxes. Turn the gear if necessary by
the motor pinion, axis 1.
7 Refit the base with the attachment screws Shown in figure Location of gearbox
and washers, gearbox unit. unit on page 246
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.

4 Repair
Continued

8 Refit the bottom plate with its attachment Shown in the figure Location of gear-
screws. box unit on page 246
9 Strap the gearbox unit as in the removal in- See section Removal, gearbox unit on
struction page 247
10 Lift the gearbox unit together with the base
and use the hoisting block to tip the com-
plete assembly backward by 90°, into nor-
mal mounting position.
11 Refit the robot to the foundation.
12 Refit the complete arm system. Detailed in section Replacement of
complete arm system on page 155
13 Refit the parallel arm. Detailed in section Refitting, parallel
arm/bearing on page 195
14 Refit the tie rod. Detailed in section Refitting, tie rod on
page 191
15 Refit the cable harness and serial measur- Detailed in sections Refitting, cabling
ing board. axes 1-3 on page 146
calibration tools.
page 263.
17
DANGER

on page 89.

4 Repair
4.8.2 Adjusting play on axis 4, intermediate gear
Illustration, adjusting play

In order to adjust the play on axis 4, the gear must be accessible. The figure below
shows the parts in the upper arm housing that must be removed/unlocked.
xx0300000191
A Cover
B Attachment screws, cover
C Screws, 3 pcs
Required equipment

Flange sealing 12340011- Loctite 574
116
tions below.
CAUTION

4 Repair
Continued
Adjusting play, axis 4

The procedure below details how to adjust the play for the intermediate gear of
axis 4.
1
DANGER
Turn off all:

working area.
2 Remove the motors for axes 4, 5 and 6. Detailed in section Removal of motor,
axes 4, 5 and 6 on page 232.
3 Remove the cover. Shown in the figure Illustration, adjust-
ing play on page 252.
4 Unlock the three screws. Shown in the figure Illustration, adjust-
ing play on page 252.
5 Rotate axis 4 to find the highest position of
the gear on the upper arm tubular.
6 Tighten the three screws again. 3 pcs, tightening torque: 69 Nm.
7 Apply flange sealing to the cover and refit Art. no. is specified in Required
it with its attachment screws and washers. equipment on page 252.
10 pcs: M8x40. Tightening torque: 24
Nm.

4 Repair
4.9.1 Repair routines
4.9 Additional repair routines for Foundry Prime
Overview
Robots working with water jet cleaning have special tightness for water jet cleaning
application and require special repair routines to maintain the tightness level. The
repair must be done according to the repair chapter with the additions described
in the following procedures.
Required equipment
Follow the instruction in the Repair chapter, with the following additional measure.
Equipment Article number
Cable strap 21662055-3
Drill diameter 8.8 mm
CAUTION
Replacement of motor axes 1-3

The following procedure details how to replace motors axes 1-3.
Action Note
1 Apply Sikaflex 521FC on both
sides of the gasket between motor
and cable box before assembling
the cable box.
xx0600003111
• A: Sikaflex
• B: Gasket
2 Cut the projecting part of the gas-
ket with a knife.

4 Repair
Continued
Action Note
3 Apply Sikaflex 521FC outside the
gasket and the cover plate around
the motor.
xx0600003112
• A: Sikaflex
4 Apply Sikaflex 521FC underneath
the cover attachment screw heads.
xx0600003113
• A: Sikaflex

4 Repair
Continued
Replacement of cable harness to motor axes 1-3 and 4-6

The following procedure details how to replace motor cabling axes 1-3 and 4-6.
Action Note
1 Drill and tap holes in the cable boxes for the Cable box, motor unit axes 1-3
air fittings before assembling a new cable
harness.
Drill diameter: 8.8mm
Thread: 1/8" pipe thread
xx0600003114
• A: Air connection on motor cable

box axis 1.
• B: Air connection on motor cable
box axis 2 and 3 (not used earth
connection.
Cable box, motor unit axes 4-6
Additional r
• A: Air connection on motor cable

box axis 4-6

4 Repair
Continued
Replacement of balancing device

The following procedure details how to replace the balancing device.
Action Note
1 Before refitting the balancing device in the
robot, apply Mercasol on both side of the ear
and both side of the washers.
xx0600003123
• A: Mercasol
Replacement of air hose (Required equipment)
7
5
6
4 2
xx0600003342

4 Repair
Continued
Equipment Article number

Elbow fitting 3HAC026511-001/ 1 Pos 6 in figure above
Rubber clamp 3HAC026523-001
T-plug connector 3HAC026515-001/ 2 Pos 3 in figure above
Y-plug connector 3HAC026514-001/ 3 Pos 2 in figure above
Bulkhead plug connector 3HAC026513-001/ 1 Pos 1 in figure above
Air hose 3HAC062050-001 According to table: Pneumatic
house Length 7500 mm
Straight plug connector 3HAC026516-001/ 1 Pos 4 in figure above
Straight fitting 3HAC026507-001/ 4 Pos 5 in figure above
Adapter 3HAC027569-001/ 1 Pos 7 in figure above
xx0600003343
Pneumatic house Article number Note

3HAC062050-001
A 140 mm From the Bulkhead plug in the front plate to the
T-plug connector for the SMB box, se step 1 and
2 in Replacement of air hose on page 259
B 270 mm From the T-plug connector to the stright plug
connector in the SMB box.
C 3050 mm From the T-plug connector through the base and
up to the Y-plug connector at the motors of axis
4,5,6, se step 3-5 in Replacement of air hose on
page 259.
D 40 mm From the Y-plug connector at axis 4,5,6 motors
to the straight fitting in the motor cover axis 4,5,6.
E 1750 mm From the Y-plug connector at axis 4,5,6 motors
to the the Y-plug connector at for the motors of
axis 3, se step 6 in Replacement of air hose on
page 259.
F 425 mm From the Y-plug connector at axis 3 motors to the
straight fitting in the motor cover axis 3.
4 Repair
Continued
Pneumatic house Article number Note

3HAC062050-001
G 80 mm From the Y-plug connector at axis 3 to the Y-plug
connector for the balancing cylinder.
H 460 mm From the Y-plug connector for the balancing cyl-
inder to the elbow fitting in the bak of the balan-
cing cylinder, se step 7 in Replacement of air hose
on page 259.
K 220 mm From the Y-plug connector for the balancing cyl-
inder to the T-plug connector for axis 1 and axis
2.
L 140 mm From the T-plug connector to the straight fitting
in the motor cover axis 1.
M 365 mm From the T-plug connector to the straight fitting
in the motor cover axis 2.
N 150 mm To the Bulkhead plug in the front plate.
Replacement of air hose

The following procedure details how to replace the air hose.
Action Note
1 The air is let in via the cover of the rear side
of the foot where a bulkhead plug for Ø6mm
plastic hose is mounted.
A plastic hose is drawn from the bulkhead
plug to a T-plug connector and led to the
SMB compartment.
Additional r
2 The hose is drawn through a drilled hole in

the rubber sealing and firmly tightened with
a straight fitting.
Additional r

4 Repair
Continued
Action Note
3 In the base an extra ring of the hose is made
so that full movement for axis 1 is guaran-
teed.
Additional r
4 The plastic hose is drawn from the T-plug

connector up through axis 1.
A hole is drilled in the cable guide axis 1 for
the air hose. A bulkhead is mounted in the
hole to prevent wear on the hose.
The hose must be able to run free in the
bulkhead.
Additional r
5 The hose continue through the lower arm

and is connected to a Y-plug connector at
the upper arm housing.
xx0600003120

4 Repair
Continued
Action Note
6 The hose is led back down the lower arm to
motors axis 1-3 from the Y-plug connector.
The air is distributed via a Y-plug connector
and a T-plug connector to the cable boxes
xx0600003121
xx0600003122
7 From the Y-plug connector for the balancing

cylinder to the elbow plug in the back of the
balancing cylinder.
xx0600003344

5 Calibration
5.1 When to calibrate
5 Calibration
5.1 When to calibrate
When to calibrate
The system must be calibrated if any of the following situations occur.
The resolver values are changed

If resolver values are changed, the robot must be re-calibrated using the calibration
methods supplied by ABB. Calibrate the robot carefully with standard calibration,
according to information in this manual.
If the robot has absolute accuracy calibration, it is also recommended, but not
always necessary to calibrate for new absolute accuracy.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.
The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on IRC5 robots 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 and controller are
connected at the first installation.
The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reachability of a robot
is changed, it needs to be re-calibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.

5 Calibration
5.2 Calibration methods
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration Calibration Pendulum
position. Levelmeter calibration
Standard calibration data is found on the SMB (alternative method)
(serial measurement board) or EIB in the robot.
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at synchronization posi-
al) tion, the Absolute accuracy calibration also
compensates for:
• Mechanical tolerances in the robot
structure
• Deflection due to load
Absolute accuracy calibration focuses on pos-
itioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the serial measurement board (SMB) or
other robot memory.
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. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with Absolute accuracy has
a sticker next to the identification plate of the
robot (IRC5).
To regain 100% Absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy after repair or maintenance that
affects the mechanical structure.
xx0400001197
Optimization Optimization of TCP reorientation perform- Wrist Optimization

ance. The purpose is to improve reorientation
accuracy for continuous processes like weld-
ing and gluing.
Wrist optimization will update standard calib-
ration data for axes 4 and 5.

5 Calibration
Continued
Brief description of calibration methods

Calibration Pendulum method
Calibration Pendulum is a standard calibration method for calibration of many of
ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).
Two different routines are available for the Calibration Pendulum method:
• Calibration Pendulum II
• Reference calibration
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.
Wrist Optimization method

Wrist Optimization is a method for improving reorientation accuracy for continuous
processes like welding and gluing and is a complement to the standard calibration
method.
The actual instructions of how to perform the wrist optimization procedure is given
on the FlexPendant.
Levelmeter calibration - alternative method

Levelmeter calibration is referred to as the alternative method for calibration of
ABB robots because of the less accurate values obtained during calibration. The
method uses the same principles as Calibration Pendulum, but does not have as
good of mechanical tolerances to the toolkit parts as the standard method with
Calibration Pendulum.
This method may, after calibration, require modifications in the robot program and
is therefore not recommended.
The calibration equipment (Levelmeter 2000) for levelmeter calibration is ordered
as separate parts for each robot, and includes the Operating manual - Levelmeter
Calibration, which describes the method and the different routines further.
CalibWare - Absolute Accuracy calibration

The CalibWare tool guides through the calibration process and calculates new
compensation parameters. This is further detailed in the Application
manual - CalibWare Field.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after replacements that do not include taking apart the robot
structure, standard calibration is sufficient.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 296.
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.

5 Calibration
5.3 Synchronization marks and synchronization position for axes
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
Synchronization marks, IRB 4400

The calibration marks for axes 2, 3, 4 and 5 are marked using punch mark tools.
xx0300000209
A Punch, axis 2, 3HAB 1521-1

B Punch, axis 3, 3HAB 1522-1

5 Calibration
Continued
C Punch, axis 4, 3HAB 1523-1 (there are two different versions of the marks, as
shown in the figure)
D Punch, axis 5, 3HAB 1524-1

5 Calibration
5.4 Calibration movement directions for all axes
5.4 Calibration movement directions for all axes
Overview
When calibrating, the axis must consistently be run towards the calibration position
in the same direction in order to avoid position errors caused by backlash in gears
and so on. Positive directions are shown in the graphic below.
Calibration service routines 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

5 Calibration
5.5 Updating revolution counters on IRC5 robots
Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Coupled axes
When updating the revolution counters for a coupled axis, also the axis it is coupled
to needs to be at its synchronization position for the update to be correct; i.e. axis
4 needs to be in synchronization position when updating axis 5 and 6.
With reversed coupled joints, the relationship is the opposite, i.e. axis 4 needs to
be in synchronization position to update axis 3.
Coupled axes
IRB 910 SC
IRB 1600ID
IRB 1660ID
IRB 2600ID
IRB 4450S
IRB 1410
IRB 1520
IRB 1600
IRB 2400
IRB 2600
IRB 4400
IRB 4600
IRB 140
Axis 4, 5, 6 x x x x x x x
Axis 5, 6 x x x x x
Axis 4, 3 x
Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.
Action Note
1 Select axis-by-axis motion mode.
2 Jog the manipulator to align the synchron- See Synchronization marks and synchron-
ization marks. ization position for axes on page 266.
IRB 140, 1400, 2400, 4400, 6600ID/6650ID,
6640ID: Axes 5 and 6 must be positioned
together!
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the TPU on page 270 (BaseWare 4.0).
Step 2 - Updating the revolution counter
with the FlexPendant on page 272.
Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important
to make sure that axes 4 and 6 of the following mentioned manipulators are
positioned correctly. The axes can be calibrated at the wrong turn, resulting in an
incorrect manipulator calibration.
Make sure the axes are positioned according to the correct calibration values, not
only according to the synchronization marks. The correct values are found on a

5 Calibration
Continued
label, located either on the lower arm, underneath the flange plate on the base or
on the frame.
At delivery the manipulator is in the correct position. Do NOT rotate axis 4 or 6 at
power up before the revolution counters are updated.
If one of the following mentioned axes are rotated one or more turns from its
calibration position before updating the revolution counter, the correct calibration
position will be lost due to non-integer gear ratio. This affects the following
manipulators:
Manipulator variant Axis 4 Axis 6
IRB 4400 No No
If the synchronization marks seem to 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).
Action Note
1 Press the button Miscellaneous then ENTER to select the service
window.
xx0100000194
2 Select Calibration from the View menu.

The Calibration window appears.
If there is more than one unit connected to the manipulator, they will
be listed in the window.
xx0100000201

5 Calibration
Continued
Action Note
3 Select the desired unit and choose Rev Counter Update from the Calib
menu.
The Revolution Counter Update window appears.
xx0100000202
4 Select the desired axis and press Incl to include it (it will be marked
with an x) or press All to select all axes.
5 Press OK when all axes that are to be updated are marked with an x.
CANCEL returns to the Calibration window.
6 Press OK again to confirm and start the update.
CANCEL returns to the Revolution Counter Update window.
7 At this point, it is recommended that the revolution counter values are Not required.
saved to a diskette.
8
CAUTION
If a revolution counter is incorrectly updated, it will cause incorrect

manipulator positioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update.
How to perform the check is detailed in section Checking the synchron-
ization position on page 274.

5 Calibration
Continued
Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).
Action
1 On the ABB menu, tap Calibration.
xx1500000942
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943

5 Calibration
Continued
Action
3 A screen is displayed, tap Rev. Counters.
en0400000771
4 Tap Update Revolution Counters....

A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
5 Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
6 A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the selected revolution counters and removes the tick from
the list of axes.
7
CAUTION
If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 274.

5 Calibration
5.6 Checking the synchronization position
Introduction
Check the synchronization position of the robot before beginning any programming
of the robot system. This may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the FlexPendant.
Using a MoveAbsJ instruction on the TPU, S4Cplus

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 Create the following program:
MoveAbsJ [[0,0,0,0,0,0], [9E9,
9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, z50, Tool0
2 Run the program in manual mode.

3 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolution synchronization position for axes
counters. on page 266 and Updating revolution
counters on IRC5 robots on
page 269.
Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 On ABB menu tap Program editor.
2 Create a new program.
3 Use MoveAbsJ in the Motion&Proc menu.
4 Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0
5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 266 and Updating revolution
counters on IRC5 robots on
page 269.

5 Calibration
Continued
Using the jogging window on the TPU, S4Cplus

Use this procedure to jog the robot to synchronization position of all axes.
Action Illustration/Note
1 Open the Jogging window.
xx0100000195
2 Select running axes-by-axes.
xx0100000196
3 Manually run the robot axes to a position

where the axis position value read on the
TPU, is equal to zero.
4 Check that the synchronization marks for the See Synchronization marks and syn-
axes align correctly. If they do not, update chronization position for axes on page 266
the revolution counters. and Updating revolution counters on
IRC5 robots on page 269.
Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 On the ABB menu, tap Jogging.
2 Tap Motion mode to select group of axes
to jog.
3 Tap to select the axis to jog, axis 1, 2, or
3.
4 Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
5 Check that the synchronization marks for See Synchronization marks and synchron-
the axes align correctly. If they do not, up- ization position for axes on page 266 and
date the revolution counters. Updating revolution counters on IRC5 ro-
bots on page 269.

5 Calibration
5.7 Calibrating with Calibration Pendulum method
5.7 Calibrating with Calibration Pendulum method
Where to find information for Calibration Pendulum

Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.

5 Calibration
5.8 Calibrating with Wrist Optimization method
When to run Wrist Optimization

Wrist Optimization routine is run to improve TCP reorientation performance.
Calibrating the robot with standard calibration method overwrites the optimized
positions of axes 4, 5. Re-run the Wrist Optimization routine after standard
calibration to re-achieve the optimized positions of the wrist axes.
Overview of the calibration procedure on the FlexPendant

The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure sequence.
After the calibration method has been called for on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine Wrist Optimization.
2 Modify targets for 4-point tool frame definition, in Wrist Optimization routine.
Tip
Select positions with large reorientations around the TCP. For best results,
make sure that axis 4 and 5 have large movements.
a Jog the robot to an appropriate position,
A, for the first approach point.
Use small increments to accurately posi-
tion the tool tip as close to the reference
point as possible.
b Tap Modify Position to define the point.
c Repeat for each approach point to be
defined, positions B, C, and D.
Jog away from the fixed world point to
achieve the best result. Just changing the
tool orientation will not give as good a
result.
en0400000906
3 Improved calibration data to the wrist axes is identified and presented.

4 Optimized positions for the wrist axes are presented.

5 Calibration
Continued
5 The robot moves to the optimized positions for the wrist axes and
automatically overwrites previous calibration data.
WARNING
Robot moves automatically when pressing Calibrate.
6 Wrist optimization is finished.

7 Redefine / verify TCP for all tools.

5 Calibration
5.9 Additional calibration instruction, IRB 4400
5.9 Additional calibration instruction, IRB 4400
Instruction
Before updating the revolution counters (coarse calibration) on IRB 4400, the
stainless steel metal ring on axis 4 need to be removed.
Illustration
C
B
xx0600003124
A Upper arm
B Stainless steel ring
C Hose clamp

6 Decommissioning
6.1 Introduction to decommissioning
6 Decommissioning
6.1 Introduction to decommissioning
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
Note
The decommissioning process shall be preceded by a risk assessment.
Disposal of materials used in the robot

All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.
See also Environmental information on page 282.
Transportation
Prepare the robot or parts before transport, this to avoid hazards.

6 Decommissioning
6.2 Environmental information
Introduction
ABB robots contain components in different materials. During decommissioning,
all materials should be dismantled, recycled, or reused responsibly, according to
the relevant laws and industrial standards. Robots or parts that can be reused or
upcycled helps to reduce the usage of natural resources.
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Materials used in the product

The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Aluminium Covers, synchronization brackets

Batteries, Lithium Serial measurement board
Cast iron/nodular iron Base, lower arm, upper arm
Copper Cables, motors
Neodymium Brakes, motors
Nickel Turning disc (foundry)
Oil, grease Gearboxes
Plastic/rubber Cables, connectors, drive belts, and so on.
Steel Gears, screws, base frame, and so on.

6 Decommissioning
Continued
Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.
Also note that:
• Spills can form a film on water surfaces causing damage to organisms.
Oxygen transfer could also be impaired.
• Spillage can penetrate the soil causing ground water contamination.

6 Decommissioning
6.3 Decommissioning of balancing device
General
There is much energy stored in the balancing device. Therefore a special procedure
is required to disassemble it. The coil springs inside the balancing device exert a
potentially lethal force unless disassembled properly.
The device must be disassembled by a decommissioning company.
Required equipment
Equipment Article num- Note

ber
Standard toolkit - Content is defined in section Standard
tools on page 295.
Protective clothing that also covers - Must protect against spatter of sparks
face and hands and flames.
Cutting torch with a long shaft - For opening housing and cutting coils.
The long shaft is a safety requirement.
Other tools and procedures may be These procedures include references
required. See references to these to the tools required.
procedures in the step-by-step 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.
Action Note
1 Remove the balancing device from the robot. Detailed in section Replacement of balan-
cing device on page 197.
2 Send the device to a decommissioning Make sure the decommissioning com-
company. pany is well informed about the stored
energy built up by high tensioned com-
pression springs and that the device
contains some grease.
The following procedure contains useful
information about decommissioning.

6 Decommissioning
Continued
Decommissioning at decommissioning company, balancing device

The instruction below details how to decommission the balancing device. Contact
ABB Robotics for further consultation.
Action Note
1
DANGER
There is stored energy built up by high

tensioned compression springs inside the
balancing device! When a coil is cut the
released tension creates a spatter of
sparks and flames.
The working area must be free of flam-
mable materials. Position the balancing
device so that the spatter will be directed
away from personnel.
2 Clamp the device at the working location.

Place the device at ground level so that
the hole and spring coils are cut from a
safe distance and somewhat from above.
3
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!
4 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft.
figure. 250 mm
80 mm
xx0700000730
5 • Outer spring: cut at least five coils! Use a cutting torch with a long shaft.
• Middle spring: cut at least four coils!
• Inner spring: cut at least four coils!
6 Double-check the number of coils cut and
make sure all the tension in the springs is
removed.
Double-check the number of coils cut and
make sure all the tension in the springs is
removed.

6 Decommissioning
6.4 Scrapping of robot
6.4 Scrapping of robot
Note
The decommissioning process shall be preceded by a risk assessment.
Important when scrapping the robot
DANGER
The risk assessment should consider hazards arising in the decommissioning,

such as, but not limited to:
• Always remove all batteries. If a battery 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.
• A used robot does not have the same performance as on delivery. Springs,
brakes, bearings, and other parts might be worn or broken.

7 Reference information
7.1 Introduction
7.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

7.2 Applicable standards
Note
The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.
General
The product is designed in accordance with ISO 10218-1:2011, Robots for industrial
environments - Safety requirements -Part 1 Robots, and applicable parts in the
normative references, as referred to from ISO 10218-1:2011. In case of deviations
from ISO 10218-1:2011, these are listed in the declaration of incorporation which
is part of the product delivery.
Normative standards as referred to from ISO 10218-1
Standard Description
ISO 9283:1998 Manipulating industrial robots - Performance criteria and related
test methods
ISO 10218-2 Robots and robotic devices - Safety requirements for industrial
robots - Part 2: Robot systems and integration
ISO 12100 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design
ISO 13850 Safety of machinery - Emergency stop - Principles for design
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
Deviations from ISO 10218-1:2011 for IRC5 with MultiMove

A deviation exists towards ISO 10218-1:2011, paragraph 5.9 Control of simultaneous
motion, for the option MultiMove. See the application manual for MultiMove.
Region specific standards and regulations
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require-
ments
Other standards used in design
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments

Continued
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
standards – Emission standard for industrial environments
ISO 13732-1:2006 Ergonomics of the thermal environment - Part 1
IEC 60974-1:2012 i Arc welding equipment - Part 1: Welding power sources
IEC 60974-10:2014 i Arc welding equipment - Part 10: EMC requirements
ISO 14644-1:2015 ii Classification of air cleanliness
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots.
ii Only robots with protection Clean Room.

7.3 Unit conversion
7.3 Unit conversion
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

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

Gleitmo is a special surface treatment to reduce the friction when tightening the
screw joint. It is recommended by ABB for M6-M20 screw joints. Screws treated
with Gleitmo may be reused 3-4 times before the coating disappears. After this the
screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber
type should be used.
Generally, screws are lubricated with Gleitmo 603 mixed with Geomet 500 or
Geomet 702 in proportion 1:3. Geomet thickness varies according to screw
dimensions, refer to the following.
Dimension Lubricant Geomet thickness
M6-M20 (any length except Gleitmo 603 + Geomet 500 3-5 μm
M20x60)
M6-M20 (any length except Gleitmo 603 + Geomet 720 3-5 μm
M20x60)
M20x60 Gleitmo 603 + Geomet 500 8-12 μm
M20x60 Gleitmo 603 + Geomet 720 6-10 μm
Screws lubricated in other ways

Screws lubricated with Molykote 1000 or Molykote P1900 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 of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.

7.4 Screw joints
Continued
Lubricant Article number

Molykote 1000 (molybdenum disulphide grease) 3HAC042472-001
Molykote P1900 (molybdenum disulphide grease) 3HAC070875-001
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
Tightening torque for oil-lubricated screws with slotted or cross-recess head screws
The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Note
A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.
Tightening torque for oil-lubricated screws with allen head screws

oil-lubricated screws with allen head screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670

7.4 Screw joints
Continued
Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M24 680 960 1150
Tightening torque for lubricated screws (Molykote, Gleitmo or equivalent) with allen head screws
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M5 8
M6 14
M8 28 35
M10 55 70
M12 96 120
M16 235 300
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

7.5 Weight specifications
7.5 Weight specifications
Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. All components exceeding 22 kg (50 lbs) are
highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory 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:
Action Note
CAUTION
The arm weighs 25 kg.

All lifting accessories used must be sized accord-
ingly.

7.6 Standard tools
7.6 Standard tools
General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.
Contents, standard toolkit
Qty Tool
1 Allen key 5-17 mm
1 Socket with ratchet
1 Box spanner set
1 Screwdriver
1 Torx socket no:20, 25, 30
1 Extension bar 100 mm
2 Puller bar
1 KM nut (KM10, KM17)
1 Lifting hoist
1 Cutting pliers
1 Torque wrench 10-470 Nm

7.7 Special tools
7.7 Special tools
General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard tools on page 295, and of special tools, listed directly in the instructions
and also gathered in this section.
Calibration equipment, Levelmeter (alternative method)

The following table specifies the calibration equipment required when calibrating
the robot with the alternative method, Levelmeter Calibration.
Description Art. no. Note
Angle bracket 68080011-LP
Calibration bracket 3HAC13908-9
Calibration tool ax1 3HAC13908-4
Measuring pin 3HAC13908-5
Sensor fixture 68080011-GM
Sensor plate 3HAC0392-1
Sync. adapter 3HAC13908-1
Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating
the robot with the Calibration Pendulum method.
Description Art. no. Note
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating
manual.

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

8 Spare Part lists
8.1 Spare part lists and illustrations
8 Spare Part lists

8.1 Spare part lists and illustrations
Location
Spare parts and exploded views are not included in the manual but delivered as
a separate document for registered users on myABB Business Portal,
www.abb.com/myABB.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.

9 Circuit diagram
9.1 Circuit diagrams
9 Circuit diagram
Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.abb.com/myABB.
See the article numbers in the tables below.
Controllers
Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 67, design 14 3HAC024120-005
Circuit diagram - Spot welding cabinet 3HAC057185-001
Manipulators

Circuit diagram - IRB 120 3HAC031408-003
Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 1600/1660 3HAC021351-003
Circuit diagram - IRB 4400/4450S 3HAC9821-1
Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001

9 Circuit diagram
Continued

3HAC029940-001
Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005
3HAC025744-001
Circuit diagram - IRB 910SC 3HAC056159-002

Index
Index D
detergents
approved, 109
A requirements, 109
Absolute Accuracy, calibration, 265
direction of axes, 268
air quality, 43
allergenic material, 30 E
aluminum environmental information, 282
disposal, 282 ESD
ambient humidity damage elimination, 54
operation, 50 sensitive equipment, 54
storage, 49
ambient temperature F
operation, 50 fire extinguishing, 31
storage, 49 FlexPendant
assembly instructions, 41 jogging to calibration position, 275
assessment of hazards and risks, 30 MoveAbsJ instruction, 274
Axis Calibration updating revolution counters, 272
procedure on FlexPendant, 277 foundation
requirements, 49
B
batteries G
disposal, 282 gearboxes
battery location of, 111
SMB, 105 grease, 34
battery pack disposal, 282
replacing, interval, 94–95
brakes H
testing function, 38 hanging
installed hanging, 30
C hazard levels, 21
cabinet lock, 31 hazardous material, 282
cabling, robot, 78 height
cabling between robot and controller, 78 installed at a height, 30
calibrating hot surfaces, 34
roughly, 269 HRA, 30
calibrating robot, 276–277 humidity
calibration operation, 50
Absolute Accuracy type, 264 storage, 49
alternative method, 265
Levelmeter calibration, 265 I
rough, 269 installation
standard type, 264 mechanical stop axis 2, 72
when to calibrate, 263 instructions for assembly, 41
calibration, Absolute Accuracy, 265 integrator responsibility, 30
calibration manuals, 265
calibration marks, 266 L
Calibration Pendulum labels
overview of method, 276 robot, 23
calibration position leak-down test, 141
jogging to, 275 Levelmeter calibration, 265
jogging to, TPU, 275 lifting accessory, 294
scales, 266 limitation of liability, 19
calibration scales, 266 Lithium
CalibWare, 264 disposal, 282
carbon dioxide extinguisher, 31 loads on foundation, 48
cast iron lock and tag, 31
disposal, 282 lubricants, 34
cleaners lubrication
approved, 109 amount in gearboxes, 111
requirements, 109 type of lubrication, 111
cleaning, 107
climbing on robot, 34 M
Cold environments, 88 magnesium
connecting the robot and controller, cabling, 78 disposal, 282
copper mechanical stop
disposal, 282 axis 2, 72

Index
MoveAbsJ instruction, 274 ESD, 54

TPU, 274 fire extinguishing, 31
release robot axes, 37
N signals, 21
national regulations, 30 signals in manual, 21
negative directions, axes, 268 symbols, 21
neodymium symbols on robot, 23
disposal, 282 test run, 89
nodular iron safety devices, 31
disposal, 282 safety equipment
mechanical stop axis 2, 72
O safety hazard
oil, 34 hydraulic system, 32
amount in gearboxes, 111 pneumatic system, 32
disposal, 282 safety signals
type of oil, 111 in manual, 21
operating conditions, 50 safety standards, 288
original spare parts, 19 scales on robot, 266
screw joints, 291
P sensitive points
paint surface damage, 104 Foundry Prime, 45
pedestal shipping, 281
installed on pedestal, 30 shut-down, 46
personnel signals
requirements, 20 safety, 21
plastic SMB battery
disposal, 282 replacing, 105
positive directions, axes, 268 special tools, 296
PPE, 20 speed
pressurized components adjusting, 88
air quality, 43 stability, 77
Foundry Prime, 42 standards, 288
product standards, 288 ANSI, 288
protection classes, 50 CAN, 288
protection type, 50 EN IEC, 288
protective equipment, 20 EN ISO, 288
protective wear, 20 start of robot in cold environments, 88
R steel
recycling, 282 disposal, 282
regional regulations, 30 storage conditions, 49
release brakes, 37 symbols
repair safety, 21
painted surface, 104 synchronization position, 269
replacements, report, 133 sync marks, 266
report replacements, 133 system integrator requirements, 30
requirements on foundation, 49
T
responsibility and validity, 19 temperatures
restricting operation, 50
working range axis 2, 72 storage, 49
revolution counters testing
storing on FlexPendant, 272 brakes, 38
storing on TPU, 270 tools
updating, 269 calibration equipment, Levelmeter, 296
risk of burns, 34 Calibration Pendulum, 296
risk of tipping, 77 for service, 296
robot torques on foundation, 48
labels, 23 TPU
protection class, 50 jogging to calibration position, 275
protection types, 50 MoveAbsJ instruction, 274
symbols, 23 updating revolution counters, 270
rubber transportation, 281
disposal, 282 troubleshooting
S oil spills, 107
safety safety, 39
brake testing, 38

Index
U W
upcycling, 282 weight, 47
updating revolution counters, 269 robot, 55, 62, 156, 158, 162–163, 166–167, 187, 194–
users 195, 199, 202, 247–248, 250
requirements, 20 working range
restricting axis 2, 72
V Wrist Optimization
validity and responsibility, 19 overview of method, 277
velocity
adjusting, 88 Z
zero position
checking, 274

ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Engineering (Shanghai) Ltd.

No. 4528 Kangxin Highway
PuDong New District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
ABB Inc.
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
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© Copyright 2004-2023 ABB. All rights reserved.

© Copyright 2004-2023 ABB. All rights reserved.

2 Installation and commissioning 41

Product manual - IRB 4400 5

3.3 Maintenance schedule ....................................................................................... 93

6 Product manual - IRB 4400

4.7.4 Adjustment of motors, axes 1-3 .................................................................. 230

7 Reference information 287

8 Spare Part lists 299

9 Circuit diagram 301

Product manual - IRB 4400 7

Overview of this manual

Who should read this manual?

Product manual scope

Continues on next page

Document name Document ID Note

Continues on next page

Continues on next page

Continues on next page

Product manual - IRB 4400 13

Product documentation, M2000/M2000A

Controller hardware option manual

14 Product manual - IRB 4400

Product documentation, IRC5

All documents can be found via myABB Business Portal, www.abb.com/myABB.

Technical reference manuals

Continues on next page

• Examples of how to use the application.

16 Product manual - IRB 4400

How to read the product manual

References to required equipment

Product manual - IRB 4400 17

1.1.1 Limitation of liability

Spare parts and equipment

Product manual - IRB 4400 19

1.1.2 Requirements on personnel

Personal protective equipment

20 Product manual - IRB 4400

1.2 Safety signals and symbols

1.2.1 Safety signals in the manual

Introduction to safety signals

WARNING Signal word used to indicate a potentially hazardous

ELECTRICAL Signal word used to indicate a potentially hazardous

CAUTION Signal word used to indicate a potentially hazardous

ELECTROSTATIC Signal word used to indicate a potentially hazardous

NOTE Signal word used to indicate important facts and

Continues on next page

Symbol Designation Significance

22 Product manual - IRB 4400

1.2.2 Safety symbols on manipulator labels

Symbols on safety labels

Continues on next page

Before disassembly, see product manual

Continues on next page

Continues on next page

Continues on next page

Chain sling with shortener