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IRB 4400 - 45
ABB IRB 4400 - 45 User Manual
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1 Safety
1.2.3.2.
Fire ext
inguish
ing
23
3HAC022
032-0
01 Revisi
on: E
© Copyright 2004-2008 ABB. All rights reserved.
1.2.3.2. F
ire
extinguishing
Use a CARBON DIOXIDE (CO
2
) extinguisher in
the event of a fire in
the robot
system
(manipulato
r or control
ler)!
24
26
Table of Contents
Default Chapter
5
Table of Contents
5
Overview
9
Product Documentation, M2000/M2000A
11
Product Documentation, M2004
12
How to Read the Product Manual
14
1 Safety
15
Introduction
15
General Safety Information
16
Safety in the Robot System
16
Safety Risks
17
Safety Risks During Installation and Service Work on Robot
17
Safety Risks Related to Tools/Workpieces
19
Safety Risks Related to Pneumatic/Hydraulic Systems
20
Safety Risks During Operational Disturbances
21
Risks Associated with Live Electric Parts
22
Safety Actions
24
Safety Fence Dimensions
24
Fire Extinguishing
25
Emergency Release of the Robot's Arm
26
Brake Testing
27
Risk of Disabling Function "Reduced Speed 250 MM/S
28
Safe Use of the Flexpendant
29
Work Inside the Manipulator's Working Range
30
Translate the Information on Safety and Information Labels
31
Safety Related Instructions
32
Safety Signals, General
32
DANGER - Moving Manipulators Are Potentially Lethal
34
DANGER - First Test Run May Cause Injury or Damage
35
WARNING - the Unit Is Sensitive to ESD
36
WARNING - Safety Risks During Work with Gearbox Oil
38
2 Installation and Commissioning
39
Introduction
39
Unpacking
40
Pre-Installation Procedure
40
Working Range, IRB 4400/45 and /60
44
Working Range, IRB 4400/L30
45
Working Range, IRB 4400/L10
46
Working Range, IRB 4400/S
47
Working Range, IRB 4450S
48
Risk of Tipping/Stability - IRB 4450S
49
On-Site Installation
50
Lifting Robot with Round Slings
50
Manually Releasing the Brakes
56
Orienting and Securing the Robot
59
Fitting Equipment on Robot
62
Loads
66
Restricting the Working Range
67
Introduction
67
Mechanically Restricting the Working Range of Axis 1
68
Mechanically Restricting the Working Range of Axis 2
71
Electrically Restricting the Working Range of Axis 3
75
Unlimited Working Range
77
Electrical Connections
79
Customer Connection on Robot
79
Customer Connections on Upper Arm
81
Additional Installation (Foundry Prime)
83
Installation of IRB4400 in a Water Jet Application
83
Commissioning (Foundry Prime)
86
Making Robot Ready for Operation (Cleanroom)
87
Additional Installation Procedure
87
3 Maintenance
89
Introduction
89
Maintenance Schedule
90
Specification of Maintenance Intervals
90
Maintenance Schedule
91
General Maintenance Activities
93
Inspection of Mechanical Stop, Axis 1
93
Inspection of Air Hoses (Foundry Prime)
95
Replacement of Battery Pack, Measuring System
96
Cleaning of Manipulator
98
Change and Checking of Oil
99
Oil in Gearbox Unit, Axis 1-2-3
99
Inspection of Oil Levels
100
Oil Change, Gearbox Axis 4
104
Oil Change, Gearbox Axis 5 and 6 (All Robot Versions Except IRB 4400/L10)
107
Oil Change, Gearbox Axis 5 and 6 (IRB 4400/L10 Only)
110
4 Repair
113
Introduction
113
General Procedures
114
Performing a Leak-Down Test
114
Mounting Instructions for Bearings
115
Mounting Instructions for Seals
116
Complete Robot
118
Replacement of Cable Harness, Axes 1-3
118
Replacement of Cable Harness, Axes 4-6
123
Replacement of Complete Arm System
130
Upper Arm
135
Replacement of Complete Upper Arm
135
Replacement of Wrist Unit
140
Replacement of Arm House Unit, Axis 4
146
Replacement of Mechanical Stop, Axis 4
149
Replacement of Signal Cabling, Upper Arm (Option 042)
152
Measuring the Play, Axis 5
156
Measuring the Play, Axis 6
159
Lower Arm
162
Replacement of Lower Arm
162
Replacement of Tie Rod
166
Replacement of Parallel Arm / Replacement of Bearing
170
Frame and Base
174
Replacement of Balancing Device
174
Replacement of Serial Measurement Unit
182
Replacement of Pushbutton Unit for Brake Release
185
Replacement of Mechanical Stop Pin, Axis 1
188
Motors
190
Replacement of Motor, Axis 1
190
Replacement of Motor, Axis 2
196
Replacement of Motor, Axis 3
200
Adjustment of Motors, Axes 1-3
204
Removal of Motor, Axes 4, 5 and 6
206
Refitting of Motor, Axis 4
209
Refitting of Motor, Axis 5
212
Refitting of Motor, Axis 6
216
Gearboxes
220
Replacement of Gearbox Unit, Axes 1-2-3
220
Adjusting Play on Axis 4, Intermediate Gear
226
Additional Repair Routines (Foundry Prime)
228
Introduction
228
Repair Routines
228
5 Calibration Information
237
Introduction
237
Calibration Methods
238
Calibration Scales and Correct Axis Position
240
Calibration Movement Directions for All Axes
242
Updating Revolution Counters
243
Checking the Calibration Position
247
Additional Calibration Instruction, IRB4400
249
Overview
251
Product Documentation, M2000/M2000A
253
Product Documentation, M2004
254
6 Reference Information
257
Introduction
257
Applicable Safety Standards
258
Unit Conversion
259
Screw Joints
260
Weight Specifications
263
Document References
264
Standard Toolkit
266
Special Tools
268
Lifting Equipment and Lifting Instructions
282
7 Part List
283
Introduction
283
Manipulator
284
Upper Arm Part, Axes 4-6
288
Serial Measurement Unit
291
Position Switch, Axis 1
292
8 Foldouts
295
Introduction
295
9 Circuit Diagram
297
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ABB IRB 4400 - 45 Specifications
General
Brand
ABB
Model
IRB 4400 - 45
Category
Robotics
Language
English
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