ABB IRB 5500 Series Motors & Pinions: IRB55003HAC026114-010 / IRB55103HAC026114-009 / IRB55003HAC026114-009

Technical Dossier

Product Details And Specifications

ABB IRB 5500 Series: Comprehensive Module Range and Technical Overview

The ABB IRB 5500 is a wall-mounted industrial paint robot engineered specifically for automotive body-in-white and exterior surface coating applications. Deployed across high-throughput production lines in automotive OEM facilities, chemical processing plants, and precision manufacturing environments, the IRB 5500 series holds a significant installed base globally — particularly in facilities requiring intrinsic safety (EX-rated) operation and compact footprint integration. Its hollow-wrist design and 7-axis kinematic configuration make it a reference platform for confined-space spray applications where conventional floor-mounted robots cannot operate. The series is produced in Sweden and remains a cornerstone of ABB Robotics' painting division, with active installations spanning North America, Europe, and Asia-Pacific.

The Evolution of IRB 5500 Architecture

The IRB 5500 platform was introduced as a successor to ABB's earlier IRB 5400 paint robot series, incorporating a redesigned axis drive train and updated servo motor specifications to support higher payload and improved path accuracy. Early production units (pre-2010) used a first-generation axis motor assembly with a separate pinion interface; subsequent revisions consolidated the motor-and-pinion sub-assembly into a single replaceable unit — reflected in part numbers such as 3HAC026114-010 and 3HAC026114-009. The controller pairing evolved from the S4C+ platform to the IRC5 Paint controller, introducing digital fieldbus communication (DeviceNet, Profibus) and later EtherNet/IP compatibility. Axis 1–3 drive modules were redesigned in the mid-2010s to accommodate higher duty-cycle demands in 24/7 automotive production. Compatibility between early and late mechanical revisions requires verification of the robot's mechanical unit serial number and software version before substitution. The IRB 5500 series is currently in its mature lifecycle phase; ABB continues to supply spare parts and provide service support, but new robot sales have transitioned toward the IRB 5500-22 and IRB 5500-27 variants with updated reach and payload ratings.

IRB 5500 Full Catalog & Functionalities (SKU List)

The following SKUs represent the core spare parts and sub-assemblies for the IRB 5500 series, organized by functional category. All part numbers are ABB OEM references.

Axis Drive Motors & Pinion Assemblies

• 3HAC026114-010: Axis motor inc. pinion, IRB 5500-3 — primary axis drive unit for axis 1 rotation on the IRB 5500-3 variant.
• 3HAC026114-009: Axis motor inc. pinion, IRB 5500-3 / IRB 5510-3 — cross-compatible motor-pinion assembly for axis drive on both IRB 5500-3 and IRB 5510-3 mechanical units.
• 3HAC026114-001: Motor unit, axis 2 — servo motor assembly for axis 2 articulation on standard IRB 5500 configurations.
• 3HAC026114-002: Motor unit, axis 3 — servo motor for axis 3 upper arm drive.
• 3HAC026114-003: Motor unit, axis 4 — wrist rotation drive motor.
• 3HAC026114-004: Motor unit, axis 5 — wrist bend servo motor assembly.
• 3HAC026114-005: Motor unit, axis 6 — wrist turn motor for end-effector orientation.

Gearboxes & Mechanical Transmission

• 3HAC028357-001: Gearbox, axis 1 — primary rotation gearbox for base axis on IRB 5500.
• 3HAC028357-002: Gearbox, axis 2 — lower arm transmission gearbox.
• 3HAC028357-003: Gearbox, axis 3 — upper arm gearbox assembly.
• 3HAC025562-001: Hollow wrist unit — complete 3-axis hollow wrist assembly for paint application tooling pass-through.

IRC5 Paint Controller Modules

• 3HAC025338-001: Drive unit, IRC5 Paint — axis drive module for IRC5 Paint controller cabinet.
• 3HAC026254-001: Main computer unit (MCU), IRC5 — central processing board for IRC5 Paint controller.
• 3HAC025466-001: I/O module, digital 24VDC — 16-channel digital I/O board for process signal integration.
• 3HAC025466-002: I/O module, analog — 4-channel analog I/O for paint flow and atomizer control signals.
• 3HAC026255-001: Power supply unit, IRC5 Paint — 24VDC regulated PSU for controller logic and I/O bus.

Cables & Harnesses

• 3HAC025337-001: Axis cable harness, lower arm — complete cable set for axes 1–3 on IRB 5500.
• 3HAC025337-002: Axis cable harness, upper arm — cable assembly for axes 4–6 and hollow wrist.

Sourcing Hard-to-Find & Obsolete IRB 5500 Parts

DriveKNMS maintains a dedicated inventory program for IRB 5500 series components, including parts that have been discontinued from ABB's standard supply chain. As the IRB 5500 platform enters its extended service lifecycle, procurement of axis motors, gearboxes, and controller modules through standard distribution channels becomes increasingly unreliable. DriveKNMS sources verified OEM and compatible replacement units through a global network of industrial surplus suppliers, decommissioned robot buyback programs, and authorized refurbishment partners. For end-users operating IRB 5500 installations beyond the standard 10-year service window, DriveKNMS provides lifecycle extension support including cross-reference verification, firmware compatibility checks, and documentation of mechanical revision levels. Customers requiring long-lead or single-source components — including 3HAC026114-010, 3HAC026114-009, and associated gearbox assemblies — are encouraged to submit a parts request with robot serial number and axis configuration for accurate cross-referencing.

Quality Control for the IRB 5500 Range

All IRB 5500 series components processed by DriveKNMS undergo a structured inspection and functional verification protocol prior to dispatch. Axis motor and pinion assemblies are inspected for bearing wear, encoder integrity, and pinion tooth profile condition using calibrated measurement tools. Gearbox units are tested for backlash within ABB-specified tolerances and checked for lubricant contamination or seal degradation. IRC5 Paint controller modules — including drive units, MCUs, and I/O boards — are bench-tested under simulated load conditions using dedicated test rigs configured for the IRC5 backplane bus architecture. Cable harnesses are continuity-tested and inspected for insulation integrity, particularly critical in EX-rated (explosion-proof) variants where cable sheath condition directly affects zone classification compliance. Each unit is issued a condition report documenting test results, revision level, and any replaced sub-components before shipment.