ABB IRB 4400/60 User manual

ROBOTICS
Product manual
IRB 4400

Trace back information:
Workspace R18-1 version a9
Checked in 2018-03-22
Skribenta version 5.2.025

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

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2004-2018 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
13Product documentation, M2000/M2000A .........................................................................................
14Product documentation, IRC5 ..........................................................................................................
16How to read the product manual ......................................................................................................
171 Safety
171.1 General safety information ..................................................................................
171.1.1 Limitation of liability .................................................................................
201.1.2 Protective stop and emergency stop ...........................................................
211.2 Safety actions ...................................................................................................
211.2.1 Fire extinguishing ....................................................................................
221.2.2 Emergency release of the robot axes ..........................................................
231.2.3 Make sure that the main power has been switched off ....................................
241.3 Safety risks ......................................................................................................
241.3.1 Safety risks during installation and service work on robots ..............................
261.3.2 Moving robots are potentially lethal ............................................................
271.3.3 First test run may cause injury or damage ....................................................
281.3.4 Work inside the working range of the robot ..................................................
291.3.5 Enabling device and hold-to-run functionality ...............................................
301.3.6 Risks associated with live electric parts .......................................................
321.3.7 The unit is sensitive to ESD .......................................................................
331.3.8 Hot parts may cause burns .......................................................................
341.3.9 Safety risks related to pneumatic/hydraulic systems ......................................
351.3.10 Brake testing ..........................................................................................
361.3.11 Safety risks during handling of batteries ......................................................
371.3.12 Safety risks during work with gearbox lubricants (oil or grease) .......................
391.4 Safety signals and symbols .................................................................................
391.4.1 Safety signals in the manual ......................................................................
411.4.2 Safety symbols on product labels ...............................................................
472 Installation and commissioning
472.1 Introduction ......................................................................................................
482.2 Installation and operational requirements for Foundry Prime robots ............................
522.3 Unpacking .......................................................................................................
522.3.1 Pre-installation procedure .........................................................................
562.3.2 Working range ........................................................................................
592.4 On-site installation ............................................................................................
592.4.1 Lifting robot with roundslings ....................................................................
622.4.2 Manually releasing the brakes ...................................................................
652.4.3 Orienting and securing the robot ................................................................
682.4.4 Fitting equipment on the robot ...................................................................
682.4.4.1 Mounting equipment ....................................................................
712.4.5 Loads fitted to the robot, stopping time and braking distances .........................
722.5 Restricting the working range ..............................................................................
722.5.1 Axes with restricted working range .............................................................
732.5.2 Mechanically restricting the working range of axis 1 ......................................
762.5.3 Mechanically restricting the working range of axis 2 ......................................
792.5.4 Electrically restricting the working range of axis 3 .........................................
812.5.5 Unlimited working range ...........................................................................
832.5.6 Risk of tipping/stability .............................................................................
842.6 Electrical connections ........................................................................................
842.6.1 Customer connection on robot ...................................................................
862.6.2 Customer connections on upper arm ..........................................................
882.7 Additional installation, Foundry Prime ...................................................................
882.7.1 Installation of IRB 4400 in a water jet application ...........................................
922.7.2 Commissioning (Foundry Prime) ................................................................
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Table of contents

932.8 Start of robot in cold environments ......................................................................
953 Maintenance
953.1 Introduction ......................................................................................................
963.2 Introduction for Foundry Prime robots ...................................................................
973.3 Maintenance schedule .......................................................................................
973.3.1 Specification of maintenance intervals ........................................................
983.3.2 Maintenance schedule .............................................................................
1003.4 Inspection activities ...........................................................................................
1003.4.1 Inspecting information labels .....................................................................
1023.4.2 Inspecting Signal lamp (option) ..................................................................
1043.4.3 Inspection of mechanical stop, axis 1 ..........................................................
1063.4.4 Inspection of air hoses (Foundry Prime) ......................................................
1083.4.5 Inspection of surface treatment (Foundry Prime) ...........................................
1093.5 General maintenance activities ............................................................................
1093.5.1 Replacing the SMB battery ........................................................................
1113.5.2 Cleaning the IRB 4400 ..............................................................................
1143.6 Changing and inspecting oil ................................................................................
1143.6.1 Type of lubrication in gearboxes ................................................................
1153.6.2 Inspection of oil levels ..............................................................................
1183.6.3 Oil change, gearbox axis 4 ........................................................................
1213.6.4 Oil change, gearbox axis 5 and 6 (all robot versions) .....................................
1243.6.5 Oil change, gearbox axis 5 and 6 (IRB 4400/L10 only) ....................................
1273.7 Service Information System, M2000 ......................................................................
1273.7.1 Using the SIS system ...............................................................................
1283.7.2 Description of Service Information System (SIS) ...........................................
1313.7.3 SIS system parameters ............................................................................
1323.7.4 Setting the SIS parameters .......................................................................
1333.7.5 Reading the SIS output logs ......................................................................
1343.7.6 Exporting the SIS data .............................................................................
1354 Repair
1354.1 Introduction ......................................................................................................
1364.2 General procedures ...........................................................................................
1364.2.1 Mounting instructions for bearings .............................................................
1384.2.2 Mounting instructions for seals ..................................................................
1404.2.3 Cut the paint or surface on the robot before replacing parts ............................
1424.2.4 Performing a leak-down test ......................................................................
1434.2.5 The brake release buttons may be jammed after service work .........................
1444.3 Complete robot .................................................................................................
1444.3.1 Replacement of cable harness, axes 1-3 ......................................................
1494.3.2 Replacement of cable harness, axes 4-6 ......................................................
1564.3.3 Replacement of complete arm system .........................................................
1614.4 Upper arm .......................................................................................................
1614.4.1 Replacement of complete upper arm ...........................................................
1664.4.2 Replacement of wrist unit .........................................................................
1704.4.3 Replacement of arm house unit, axis 4 ........................................................
1734.4.4 Replacement of mechanical stop, axis 4 ......................................................
1764.4.5 Replacement of signal cabling, upper arm (option 042) ...................................
1804.4.6 Measuring the play, axis 5 .........................................................................
1834.4.7 Measuring the play, axis 6 .........................................................................
1864.5 Lower arm .......................................................................................................
1864.5.1 Replacement of lower arm ........................................................................
1904.5.2 Replacement of tie rod .............................................................................
1944.5.3 Replacement of parallel arm / Replacement of bearing ...................................
1984.6 Frame and base ................................................................................................
1984.6.1 Replacement of balancing device ...............................................................
2064.6.2 Replacement of serial measurement unit .....................................................
2104.6.3 Replacement of the brake release board ......................................................
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2144.6.4 Replacement of mechanical stop pin, axis 1 .................................................
2164.7 Motors ............................................................................................................
2164.7.1 Replacement of motor, axis 1 ....................................................................
2214.7.2 Replacement of motor, axis 2 ....................................................................
2264.7.3 Replacement of motor, axis 3 ....................................................................
2314.7.4 Adjustment of motors, axes 1-3 ..................................................................
2334.7.5 Removal of motor, axes 4, 5 and 6 ..............................................................
2354.7.6 Refitting of motor, axis 4 ...........................................................................
2394.7.7 Refitting of motor, axis 5 ...........................................................................
2434.7.8 Refitting of motor, axis 6 ...........................................................................
2474.8 Gearboxes .......................................................................................................
2474.8.1 Replacement of gearbox unit, axes 1-2-3 .....................................................
2534.8.2 Adjusting play on axis 4, intermediate gear ..................................................
2554.9 Additional repair routines for Foundry Prime ..........................................................
2554.9.1 Repair routines .......................................................................................
2635 Calibration
2635.1 When to calibrate .............................................................................................
2645.2 Calibration methods ...........................................................................................
2665.3 Synchronization marks and synchronization position for axes ...................................
2685.4 Calibration movement directions for all axes ..........................................................
2695.5 Updating revolution counters ...............................................................................
2745.6 Checking the synchronization position ..................................................................
2765.7 Additional calibration instruction, IRB 4400 ............................................................
2776 Decommissioning
2776.1 Environmental information ..................................................................................
2796.2 Decommissioning of balancing device ...................................................................
2816.3 Scrapping of robot .............................................................................................
2837 Reference information
2837.1 Introduction ......................................................................................................
2847.2 Applicable standards .........................................................................................
2867.3 Unit conversion .................................................................................................
2877.4 Screw joints ....................................................................................................
2907.5 Weight specifications .........................................................................................
2917.6 Standard tools ..................................................................................................
2927.7 Special tools ....................................................................................................
2937.8 Lifting accessories and lifting instructions ..............................................................
2958 Spare Part lists
2958.1 Spare part lists and illustrations ...........................................................................
2979 Circuit diagram
2979.1 Circuit diagrams ................................................................................................
299Index
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Table of contents

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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.
Organization of chapters
The manual is organized in the following chapters:
ContentsChapter
Safety informationSafety, service
Information about installation of the robot.Installation and commissioning
Information about maintenance work, including mainten-
ance schedules.
Maintenance
Information about repair work.Repair
Procedures that does not require specific calibration
equipment. General information about calibration.
Calibration information
Environmental information about the robot and its compon-
ents.
Decommissioning
Useful information when performing installation, mainten-
ance or repair work (lists of necessary tools, reference
documents, safety standards)
Reference information
Complete list of robot parts, shown in the partlistPart list
Continues on next page
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Overview of this manual

ContentsChapter
Detailed illustrations of the robot with reference numbers
to the part list.
Exploded views
Reference to the circuit diagram for the robot.Circuit diagram
References
NoteDocument IDDocument name
3HAC9117-1Product specification - IRB 4400
3HAC049107-001Product manual, spare parts - IRB 4400
3HAC9821-1Circuit diagram - IRB 4400/4450S
M20043HAC031045-001Operating manual - General safety information i
M20043HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
M20043HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC030421-001Application manual - CalibWare Field 5.0
3HAC042927-001Technical reference manual - Lubrication in gear-
boxes
3HAC050944-001Operating manual - Service Information System
M20043HAC051016-001Application manual - Additional axes and stand
alone controller
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition.-
Replaces previous manuals:
• Installation and Commissioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Model M2004 implemented.
Chapter Safety, service replaced with chapter Safety.A
Chapter Calibration replaced with chapter Calibration information.
Removed chapter Calibration, M2004.
Section Document references is completed with article numbers for calibration
manuals.
Yaskawa motors been added.B
Robot model IRB 4450S added.C
Foundry Prime (Water jet application) added.D
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
The protection type Clean Room is added.E
Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
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
F
Missing spare part in chapter Spare parts, section Upper arm, axes 4-6, added:
• Item 29, Gear axis 6
G
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 297.
• 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.
H
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 16.
•Some general tightening torques have been changed/added, see updated
values in Screw joints on page 287.
• Added Safety risks during handling of batteries on page 36.
• All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount of oil in
gearboxes on page 114.
• A new SMB unit and battery is introduced, with longer battery lifetime.
J
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 281.
•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.
K
This revision includes the following updates:
• Minor corrections.
L
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.
M
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
Published in release R16.2. The following updates are done in this revision:
• Corrections due to updates in terminology.
• Location of labels figure added.
N
Published in release R17.2. The following updates are made in this revision:
• Information about coupled axes in Updating revolution counters 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 93 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 143.
• Updated the description of dimensions (pos A) Mounting equipment on
page 68).
• Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
P
Published in release R18.1. The following updates are made in this revision:
• Added sections in General procedures on page 136.
• 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.
Q
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Continued

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.
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Product documentation, M2000/M2000A

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.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
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.
• 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).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
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.
• Examples of how to use the application.
Continues on next page
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Product documentation, IRC5

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.
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Product documentation, IRC5
Continued

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.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
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.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
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 17.
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.
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How to read the product manual

1 Safety
1.1 General 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 complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/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 made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Nation/region specific regulations
To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.
To be observed by the supplier of the complete system
The integrator is responsible 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 and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Continues on next page
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1 Safety
1.1.1 Limitation of liability

The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they retain work pieces in the
event of a power failure or a disturbance to the controller.
Continues on next page
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1 Safety
1.1.1 Limitation of liability
Continued

Unauthorized modifications of the originally delivered robot are prohibited. Without
the consent of ABB it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength could be affected.
CAUTION
Ensure that a gripper is prevented from dropping a work piece, if such is used.
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1 Safety
1.1.1 Limitation of liability
Continued

1.1.2 Protective stop and emergency stop
Overview
The protective stops and emergency stops are described in the product manual
for the controller.
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1 Safety
1.1.2 Protective stop and emergency stop