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4.2 General procedures

4.2.1 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.

Required equipment

Note

Article number

Equipment, etc.

-

Leak-down tester

-

Leak detection spray

Performing a leak-down test

Note

Action

Finish the refitting procedure of the motor or gear in
question.

1

Remove the upper oil plug on the gear and replace
it with the leak-down tester.

2

Regulators, which are included in the leak-down test,
may be required.

Correct value:

Use caution, apply compressed air and raise the
pressure with the knob until the correct value is
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.

3

0.2-0.25 bar (20-25 kPa)

Disconnect the compressed air supply.

4

If the compressed air is signific-
antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.

Wait for approximately 8-10 minutes and make sure
that no pressure loss occurs.

5

If any pressure drop occurred, then localize the leak
as described in step

6

If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.

Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.

7

When the leak has been localized, take the necessary
measures to correct the leak.

8

188

Product manual - IRB 4600

3HAC033453-001 Revision: Y

© Copyright 2009-2021 ABB. All rights reserved.

4 Repair

4.2.1 Performing a leak-down test

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Summary of Contents for IRB 4600

Page 1: ...ROBOTICS Product manual IRB 4600 ...

Page 2: ...Trace back information Workspace 21A version a15 Checked in 2021 04 12 Skribenta version 5 4 005 ...

Page 3: ...manual IRB 4600 60 2 05 IRB 4600 45 2 05 IRB 4600 40 2 55 IRB 4600 20 2 50 IRC5 Document ID 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty 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 f...

Page 5: ... robot with roundslings 57 2 3 2 Lifting and turning a suspended mounted robot 58 2 3 3 Manually releasing the brakes 61 2 3 4 Orienting and securing the robot 65 2 3 5 Setting the system parameters for a suspended or tilted robot 69 2 3 6 Fitting equipment on robot 76 2 3 7 Loads fitted to the robot stopping time and braking distances 77 2 3 8 Installation of signal lamp option 78 2 4 Restricting...

Page 6: ...es 5 and 6 gearboxes 179 3 4 8 Replacing SMB battery 184 3 5 Cleaning activities 184 3 5 1 Cleaning the IRB 4600 187 4 Repair 187 4 1 Introduction 188 4 2 General procedures 188 4 2 1 Performing a leak down test 189 4 2 2 Mounting instructions for bearings 191 4 2 3 Mounting instructions for sealings 194 4 2 4 Cut the paint or surface on the robot before replacing parts 195 4 2 5 The brake release...

Page 7: ... 4 5 Reference calibration 364 5 5 Calibrating with Calibration Pendulum method 365 5 6 Calibrating with Wrist Optimization method 366 5 7 Verifying the calibration 367 5 8 Checking the synchronization position 369 6 Decommissioning 369 6 1 Introduction 370 6 2 Environmental information 372 6 3 Scrapping of robot 373 7 Robot description 373 7 1 Manipulator types and variants 374 7 2 Type C of IRB ...

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

Page 9: ...tallation repair maintenance work Product manual scope The manual covers covers all variants and designs of the IRB 4600 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 Contents Chapter Safety information that must be read through before performing any install...

Page 10: ...gram IRB 4600 3HAC031045 001 Safety manual for robot Manipulator and IRC5 or OmniCore controller i 3HAC021313 001 Product manual IRC5 IRC5 with main computer DSQC 639 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC027098 001 Operating manual Emergency safety information 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HAC020738 001 Operating manual Troubleshooting IR...

Page 11: ...ange with software added in section Mechanically restricting the working range of axis 1 on page 79 The sections describing Replacing motors axes 1 through 6 has been updated Two new sections Removing motors on page287 and Refitting motors on page 295 replaces the older ones A The following updates have been made in this revision Missing text type A for armhousing 3HAC034549 005 added in chapter S...

Page 12: ...cting oil level axis 1 gearbox on page 110 Inspection of oil level on suspended robot updated in section Inspect ing oil level axis 1 gearbox on page 110 C The following updates have been made in this revision Added information about the bracket on the mechanical stop pin axis 1 has been updated in section Mechanically restricting the working range of axis 1 on page 79 Inspecting the mechanical st...

Page 13: ...justing the play of axis 4 5 and 6 motors on page 305 Added step about removing refitting axis 1 motor when replacing the axis 1 gearbox Also added information about guide pins See Repla cing gearbox axis 1 on page 306 Also minor additions concerning the mating of gearbox and motor in all such instructions New section about calibration movement directions for axes is added see Calibration movement...

Page 14: ...wrist unit see Replacing wrist unit on page 263 Added information about disconnecting the battery cable when remov ing the cable harness see Removing the complete cable harness on page 196 Added a funnel to equipment list see Changing the oil axis 3 gearbox on page 163 Added Profibus to the section about connections to extra equipment see Customer connection on robot on page 99 Some general tighte...

Page 15: ...eeves changed to Guide bushings see Dimension mounting surface and guide bushing on page 62 A new WARNING is added in the section about motor replacement informing not to mix different motor types Minor corrections K The following updates have been made in this revision Added values for restricted working range if the robot is equipped with a gearbox Type C see Mechanically restricting the working...

Page 16: ...s for Brake release board Note added to calibration chapter to emphasize the requirement of equally dressed robot when using previously created reference calib ration values Information about myABB Business Portal added Information about measuring the play in axis 5 and 6 updated Added Nickel in Environmental information R Published in release R18 2 The following updates are done in this revision ...

Page 17: ...hapter W Published in release 20C The following updates are made in this revision Added note about differences in type of oil pre filled in axis 4 gear compared to recommended oil for field maintenance Updated section about customer connections in regard to Ethernet etc See Customer connection on robot on page 99 X Published in release 21A The following updates are made in this revision Note regar...

Page 18: ...sioning 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...

Page 19: ...s The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRB 4600 19 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved Product documentation Continued ...

Page 20: ...ompleted with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list The table below shows an example of a reference to a list of required equipment from a step in a procedure Note Illustration Action Art no is...

Page 21: ...ration 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 supplie...

Page 22: ...ence 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 product manual 22 Product manual IRB 4600 3HAC033453 001 Revisi...

Page 23: ...on which if not avoided will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous ...

Page 24: ...d to indicate where to find additional information or how to do an operation in an easier way TIP 24 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 25: ...ription Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc Caution xx090000...

Page 26: ...o not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 26 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights rese...

Page 27: ... over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 4600 27 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 28: ...1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 28 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 29: ...01242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 4600 29 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 30: ...t this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 30 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Cont...

Page 31: ...ergency stops are described in the product manual for the controller For more information see Product manual IRC5 Product manual IRC5 Panel Mounted Controller Product manual IRB 4600 31 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 32: ...r 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 wor...

Page 33: ...essary 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 appl...

Page 34: ...rain 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 ...

Page 35: ... and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Product manual IRB 4600 35 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 1 Safety 1 5 1 Unexpected movement of robot arm ...

Page 36: ...king as intended Hot surfaces Surfaces can be hot after running the robot Touching the surfaces may result in burns Allow the parts to cool down before maintenance or repair Allergic reaction Elimination Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn When working with lubricants there is a risk of an allergic reac tion Allergic reaction Gearbox l...

Page 37: ...in the instructions Al ways use the type of oil specified for the product Mixing types of oil may cause severe damage to the gearbox Do not mix types of oil Run the robot before changing the gearbox oil if possible Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox Wh...

Page 38: ...perating temperatures are listed in Operating conditions robot on page 47 See safety instructions for the batteries in Material product safety data sheet Battery pack 3HAC043118 001 Unexpected movement of robot arm WARNING Hazards due to the use of brake release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator mo...

Page 39: ...ire 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 Pr...

Page 40: ...ght 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 For robots with the option SafeMove the Cyclic Brake Check routine is recommended See the manual for SafeMove in Referen...

Page 41: ...engineers A risk assessment must be done to address both robot and robot system specific hazards WARNING Hazards due to the use of brake release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety informati...

Page 42: ...e release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment 42 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 1 Safety 1 8 Decommissioning ...

Page 43: ...at all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page21 before performing any installation work Note If the IRB 4600 is connected to power always make sure that the robot is connected to protective earth and...

Page 44: ... as specified in Weight robot on page 44 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 47 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 47 7 Before taking the robot to its installation site make sure that the site conforms to Loads on f...

Page 45: ...e shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values also never reach their maximum at the same time WARNING The robot installation is restricted to the mounting options given in following load table s Floor mounted Max load emergency stop Endurance lo...

Page 46: ...n recommended Minimum resonance frequency Due to foundation stiffness consider robot mass including equipment i For information about compensating for founda tion flexibility see Application manual Control ler software IRC5 section Motion Process Mode i The minimum resonance frequency given should be interpreted as the frequency of the robot mass inertia robot assumed stiff when a foundation trans...

Page 47: ...bot Value Parameter 5 C Minimum ambient temperature 45 C Maximum ambient temperature 95 at constant temperature gaseous only Maximum ambient humidity Protection classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP 67 Manipulator protection type Standard IP 67 Manipulator protection type Foundry Plus Pr...

Page 48: ...r mounted robot xx0800000267 Pos F Pos E Pos D Pos C Pos B Pos A Variant 2051 mm 1701 mm 593 mm 1028 mm 1260 mm 2371 mm IRB 4600 60 2 05 2051 mm 1701 mm 593 mm 1028 mm 1260 mm 2371 mm IRB 4600 45 2 05 2552 mm 2202 mm 680 mm 1393 mm 1735 mm 2872 mm IRB 4600 40 2 55 2513 mm 2163 mm 665 mm 1361 mm 1696 mm 2833 mm IRB 4600 20 2 50 Continues on next page 48 Product manual IRB 4600 3HAC033453 001 Revisi...

Page 49: ...71 mm IRB 4600 60 2 05 2051 mm 1701 mm 593 mm 1028 mm 1260 mm 2371 mm IRB 4600 45 2 05 2552 mm 2202 mm 680 mm 1393 mm 1735 mm 2872 mm IRB 4600 40 2 55 2513 mm 2163 mm 665 mm 1361 mm 1696 mm 2833 mm IRB 4600 20 2 50 Continues on next page Product manual IRB 4600 49 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of ...

Page 50: ... 05 45 2 05 40 2 55 The table specifies the types and ranges of motion in every axes Range of movement Type of motion Location of motion 180 Rotation motion Axis 1 150 90 Arm motion Axis 2 75 180 Arm motion Axis 3 400 Wrist motion Axis 4 120 125 Bend motion Axis 5 400 Turn motion Axis 6 Continues on next page 50 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights r...

Page 51: ...n of motion 180 Rotation motion Axis 1 150 90 Arm motion Axis 2 75 180 Arm motion Axis 3 400 Wrist motion Axis 4 120 Bend motion Axis 5 400 Turn motion Axis 6 Product manual IRB 4600 51 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 52: ...robot in its shipping position and transportation position The position of the calibration mark A in the figure is approximate and is used as aiming aid 1 5 45 A 0 xx0800000263 WARNING The robot will be mechanically unstable if not properly secured to the foundation 52 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 2...

Page 53: ... 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 ground...

Page 54: ...d equipment Note Equipment Lifting capacity 1 000 kg Max load at 90 Overhead crane Lifting capacity roundsling 1 000 kg Length 2 m Roundslings 2 pcs Lifting Attach the roundslings as shown in the figure xx0800000262 Roundsling put folded in U shape through the lifting lug A Roundsling put folded in U shape around gearbox axis 3 B Lifting lug C Continues on next page 54 Product manual IRB 4600 3HAC...

Page 55: ...most stable position 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 5 See the figure in Lifting on page 54 Attach roundsling A to the lifting lug on the frame and put folded in a U shape on either side of the upper arm 6 See the figure in Lifting on page 54 Attach roundsling B at axis 3 gearbox by run ni...

Page 56: ...the connec tion box at the base of the robot 9 A Area where the connection box can be damaged while lifting Lifting capacity See Required equipment on page 54 Lift the robot with an overhead crane 10 56 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting robot with roundslings Continued ...

Page 57: ...ion is specified in Special tools on page 386 Any additional equipment required is specified in the instruction for the lifting accessory Contact ABB for more information How to lift and turn the robot into position for tilted position Contact ABB for more information Illustration xx1500002116 Product manual IRB 4600 57 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Instal...

Page 58: ...m Using the push button when the robot is connected to the controller This procedure details how to release the holding brakes with push buttons when the robot is connected to the controller Note Action xx0800000272 The internal brake release unit is located at the base of the robot 1 The brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered accor...

Page 59: ...n cause all brakes to be released simultaneously 1 Connect to connector R1 MP 0V to pin 12 24V to pin 11 The brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered accord ing to the numbers of the axes Release the holding brake on a particular axis by pressing the corresponding button on the push button unit and keeping it de pressed 2 See the prev...

Page 60: ... the brake cable the brake will be released imme diately when the power is switched on This may cause some unexpected robot movements 1 See chapter Circuit diagram on page393 Axes 1 2 and 3 Pos 2 24 V Pos 5 0 V xx1400001984 Connect an external 24 VDC power supply to the motor according to the figures Note Be careful not to interchange the 24V and 0V pins If they are mixed up damage can be caused t...

Page 61: ...ections Loads on foundation robot on page 45 and Requirements foundation on page 46 Hole configuration base The illustration shows the hole configuration used when securing the robot xx0800000271 Hole for guide bushing C Rear bolt holes D Continues on next page Product manual IRB 4600 61 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 3 4 Or...

Page 62: ...robot E M16 3 pcs F Guide bushings 2 pcs G Specification attachment screws The table specifies the type of securing screws and washers to be used to secure the robot to the foundation or base plate Note Dimension Securing parts Facts 6 pcs M16 x 60 installation directly on foundation Securing screws oiled 200 Nm M16 x 70 80 installation on foundation or base plate us ing guide bushings Quality 8 8...

Page 63: ...chment holes 2 CAUTION The IRB 4600 robot weighs 440 kg All lifting accessories used must be sized accordingly 3 CAUTION When the robot is put down after being lifted or transported there is a risk of it tipping if not properly secured 4 How to lift the robot is described in sec tion Lifting robot with roundslings on page 54 Lift the robot to its installation site 5 Fit two guide bushings to the r...

Page 64: ... When bolting a mounting plate or frame to a concrete floor follow the general instructions for expansion shell bolts Screw joints must be able to withstand the stress loads defined in section Loads on foundation robot on page 45 64 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 3 4 Orienting and securing the robot C...

Page 65: ...m parameters Note The mounting angle must be configured correctly in the system parameters so that the robot system can control the movements in the best possible way An incorrect definition of the mounting angle will result in Overloading the mechanical structure Lower path performance and path accuracy Some functions will not work properly for example Load Identification and Collision detection ...

Page 66: ...arameter 7 axes high performance motion is set see Technical reference manual System parameters Gamma Rotation Gamma Rotation defines the orientation of the robot foot on the travel carriage track motion Mounting angles and values The parameter Gravity Beta or Gravity Alpha specifies the mounting angle of the robot in radians It is calculated in the following way Gravity Beta A x 3 141593 180 B ra...

Page 67: ...d mounting mounting angle 15 B Suspended mounting mounting angle 180 C Continues on next page Product manual IRB 4600 67 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 3 5 Setting the system parameters for a suspended or tilted robot Continued ...

Page 68: ...nging the mounting angle of the robot The parameters belong to the type Robot in the topic Motion How to calculate a new value is detailed in Mounting angles and values on page66 The system parameters are described in Technical reference manual System parameters The system parameters are configured in RobotStudio or on the FlexPendant 68 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright ...

Page 69: ...nd or its parts Note Never drill a hole in the robot without first consulting ABB Fitting equipment on robot Load areas The shaded area indicates the permitted positions center of gravity for any extra equipment fitted in the holes intended for this purpose xx0800000275 Max load D Max load A C Max load C Max load B Max load A Variant 35 kg 15 kg 15 kg 5 kg i 15 kg IRB 4600 60 2 05 35 kg 15 kg 15 k...

Page 70: ...aximum loads must never be exceeded Fitting equipment on base and frame The illustrations show the fitting holes available for fitting extra equipment on the base and frame of the robot xx0800000276 Attachment holes on base A Center axis 2 B Continues on next page 70 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 3 6...

Page 71: ...r arm of the robot 16 3x M8 90 216 2x M8 16 A C L 0 3 190 110 80 2x M8 16 0 3 16 65 130 3x M8 190 80 B xx0800000280 Center axis 4 A Center axis 3 B Continues on next page Product manual IRB 4600 71 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 72: ...sition H and measurement C is only applicable to IRB 4600 40 2 55 and IRB 4600 20 2 50 Position H and measurement C is only applicable to IRB 4600 40 2 55 and IRB 4600 20 2 50 Attachment screws Variant 4x M8 through 60 2 05 4x M8 through 45 2 05 6x M8 through 40 2 55 6x M8 through 20 2 50 Continues on next page 72 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights...

Page 73: ... the robot xx0800000277 Note Do not remove screws indicated in the illustration below xx0800000281 Screws not to be removed Do not use these holes for fitting equipment on the wrist A Screw hole intended for swivel fitting B Continues on next page Product manual IRB 4600 73 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipmen...

Page 74: ...all the way through xx0800000282 The mounting flange has through holes with a thread only part way through the hole R 50 8 H9 0 036 0 8 min 5 x 6 0 6x M10 17 1 30 F F 0 05 C D 0 3 C D E E 63 H8 9 min 10 SECTION F F xx1600000626 Note Use attachment screws M10 quality 12 9 and 15 mm used thread length Continues on next page 74 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB...

Page 75: ...he mounting flange of the robot version IRB 4600 20 2 50 79 2x M6 110 6 12 5 12 2x M 25 A R98 D B B C 0 05 C 0 3 D 5 0 30 6x M6 6 0 6 H7 8 P P B P P C 7 31 5 H8 63 h8 10 xx0800000278 Smallest circumscribed radius axis 4 A Note Use attachment screws M6 quality 12 9 and 10 mm used thread length Product manual IRB 4600 75 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Install...

Page 76: ... 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 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 for the robot 76 P...

Page 77: ...Signal lamp See the assembly instruction delivered with the signal lamp Product manual IRB 4600 77 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 3 8 Installation of signal lamp option ...

Page 78: ...his 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 WARNING Remove the mechancial stop bracket if the robots full working range is from a mechanical stop to another mechanical stop Otherwise the mechanical sto...

Page 79: ...o correspond to the changes in the mechanical limitations of the working range The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Required equipment Note Art no Equipment etc Includes two additional stop lugs attachment screws washers and instruction See Spare part lists on page391 Mechanical stop axis 1 ...

Page 80: ...r design than Type C and Type D C Attachment screws D Washers E 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 Note Action See the figure Additional stops on page 80 for guidance Determine the position of the stop lugs 1 Continues on next page 80 Product manual IRB 4600 3HAC0334...

Page 81: ...ion DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 xx1100000091 A Attachment screw B Bracket stop axis 1 Remove the two screws holding the mechan ical stop and the bracket 2 Remove the bracket 3 Refit the attachment screws 4 Product manual IRB 4600 81 3HAC033453 001 Revision Y Copyright 2009 2021 ABB Al...

Page 82: ...ing fans The fans are installed on the motors axes 1 or 2 as shown in the figure below xx0900000135 Fan motor axis 2 A Fan motor axis 1 B Protection cover C Continues on next page 82 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 5 1 Installation of cooling fan for motors option ...

Page 83: ...tachment screws fanbox plates 9 pcs B Groove in the connector C Tightening screws fanbox 3 pcs D Continues on next page Product manual IRB 4600 83 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 5 1 Installation of cooling fan for motors option Continued ...

Page 84: ...ctite 243 Used for the three tightening screws Locking liquid Content is defined in section Standard tools on page 385 Standard toolkit See chapter Circuit diagram on page393 Circuit diagram These procedures include references to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Continues on next page 84 Produc...

Page 85: ...of the fanbox 4 See the figure in Cooling fan on page 83 Tip If there is a lack of space between motor and robot it is possible to remove part of the fanbox 5 Align the upper part of the fan with the lower part of the connection box A B C xx1000000124 Push the fanbox in line with the connection box 6 Parts A Connection box B Position where the fan shall be aligned with connection box C Fan Fit the...

Page 86: ...itting the motor cover fit the protection cover using two attachment screws for the motor cover 9 Parts A Protection cover B Fan Secure the fan cable to the protection cover with a cable strap 10 Continues on next page 86 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 5 1 Installation of cooling fan for motors option...

Page 87: ... Place the fanbox around motor axis 1 3 See the figure in Cooling fan on page 83 Refit the back plate of the fanbox 4 Fit the fanbox with two attachment screws M6x30 5 xx0900000405 Connect the fan connector to motor and fan 6 Parts A Connector signal B Connector power C Fan cable D Connector fan E Cable gland F Motor cover with fan cable Continues on next page Product manual IRB 4600 87 3HAC033453...

Page 88: ...n the Modifying options dialogue by using the Modify Controller System Wizard in the Sys tem Builder of RobotStudio Read more about modifying the system in Operating manual RobotStudio Modify the settings in RobotWare to include the cooling fans 1 88 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 5 1 Installation of ...

Page 89: ... available in English German French Spanish and Italian and can be found on the DVD delivered with the Cable guard article number 3HAC035933 001 xx1100000097 Product manual IRB 4600 89 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 5 2 Installation of Foundry Plus Cable guard option no 908 1 ...

Page 90: ...ots have the expansion container installed on delivery Expansion container xx1000000318 Cover A Attachment screw M6x16 quality 8 8 A2F 5 pcs B Oil expansion container with cover C Base D O ring D220x5 E Attachment screw M5x20 quality 8 8 A2F and washer 2 2 pcs F O ring D1 9 5 D2 1 6 G Oil plug to be removed H Required equipment Note Equipment Kit including oil Expansion container Continues on next...

Page 91: ...page 57 Lift the robot using the lifting accessory and place it in suspended position with the base free for installation work 1 Remove the cover and the o ring from the base 2 xx1500001958 Remove two existing attachment screws as shown in the figure 3 The screws must be replaced with longer screws xx1900001818 Remove the oil plug from the base 4 Continues on next page Product manual IRB 4600 91 3...

Page 92: ... plug 8 Apply some grease on the small o ring and place it in the recess on the expansion con tainer 9 xx1500001959 Place the expansion container in the base and place it so the drain holes match Tip Turn and install the container quickly to avoid oil spill 10 Secure the expansion container with the at tachment screws and washers Wipe off any oil residuals before continuing 11 Tightening torque 6 ...

Page 93: ... robot so it is not suspended 14 Turn the robot to suspended position 15 See procedure for suspended robot In specting oil level axis 1 gearbox on page 110 Inspect the oil level 16 Product manual IRB 4600 93 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 5 3 Installing an expansion container Continued ...

Page 94: ...e Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 CAUTION Components may be hot 2 Note Before opening the oil plug make certain that the oil plug is above the oil level Place the robot accordingly 3 Tip Hold a cloth or some paper over the oil plug while opening it to prevent surplus oil causing bu...

Page 95: ...he speed can be regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 1...

Page 96: ...ual for the controller see document number in References on page 10 Handles power supply to and control of the external axes motors as well as feedback from the servo system External axes cables option See the Application manual Additional axes and stand alone controller M2004 see document number in Refer ences on page 10 Robot cables These cables are included in the standard delivery They are com...

Page 97: ...meter for static floor cables A B xx1600002016 Diameter A Diameter x10 B Grounding and bonding point on manipulator There is a grounding bonding point on the manipulator base The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx1600001004 Continues on next page Product manual IRB 4600 97 3HAC033453 001 Revision Y Copyright 20...

Page 98: ...e completely pre manufactured and ready to plug in Cabling to be installed on the robot is specified in section Installation of cooling fan for motors option on page 82 98 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 8 1 Robot cabling and connection points Continued ...

Page 99: ... not exceed 10mA The customer connections are located on the robot as shown in the figure Customer connections on upper arm A B C D xx2000001659 R2 PROC1 A Air M16x1 5 24 cone sealing R2 ETHERNETi B R2 CP or R2 CBUS C R2 CS or R2 CP CS D i Use a straight ethernet connector Using an angled connector causes a collision risk with R2 CP R2 CBUS or R2 CP CS Continues on next page Product manual IRB 460...

Page 100: ... R2 ETHERNETi B R2 CP or R2 CBUS C R2 CS or R2 CP CS D Signal lamp E R3 H1 R3 H2 inside the arm house not shown in figure i Use a straight ethernet connector Using an angled connector causes a collision risk with R2 CP R2 CBUS R2 CS or R2 CP CS Continues on next page 100 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2...

Page 101: ...nnections base with 7th axis A B E C D xx2000001637 R1 CP CS A R1 PROC1 Air M16x1 5 B R1 ETHERNET C R1 SMB D R2 FB7 E Continues on next page Product manual IRB 4600 101 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 8 2 Customer connection on robot Continued ...

Page 102: ...s To connect power and signal conductors to the robot base upper arm connectors the following parts are recommended Content Art no Connector Connection set Sockets for cable area of 0 14 2 5 mm Hood foundry Hinged frame hood Multicontact module female 3HAC16667 1 R1 CP CS PROC1 on base Hose coupling M12 connector male 3HAC033181 001 R1 ETHER NET Connector set on base Pins for cable area 0 21 0 93 ...

Page 103: ...R2 CS A XP5 1 1 CSA R1 CP CS b2 R2 CS B XP5 1 2 CSB R1 CP CS b3 R2 CS C XP5 2 1 CSC R1 CP CS b4 R2 CS D XP5 2 2 CSD R1 CP CS b5 R2 CS E XP5 2 3 CSE R1 CP CS b6 R2 CS F XP5 2 4 CSF R1 CP CS b7 R2 CS G XP5 1 9 CSG R1 CP CS b8 R2 CS H XP5 1 10 CSH R1 CP CS b9 R2 CS J XP5 1 11 CSJ R1 CP CS b10 R2 CS K XP5 1 12 CSK R1 CP CS b11 R2 CS L XP5 1 3 CSL R1 CP CS b12 R2 CS M XP5 1 4 CSM R1 CP CS b13 R2 CS N X...

Page 104: ... Upper arm R2 Customer Ter minal Controller Signal name R1 CP CS b23 R2 CS Y XP5 2 10 CSY R1 CP CS b24 R2 CS Z XP5 2 11 CSZ 104 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 2 Installation and commissioning 2 8 2 Customer connection on robot Continued ...

Page 105: ...ty 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 21 before performing any service work Note If the IRB 4600 is connected to power always make sure that the IRB...

Page 106: ...d 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 Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours ABB Con...

Page 107: ... the IRB 4600 on page 184 Robot Cleaning Every 12 months Oil level in axis 1 gearbox Inspection Every 12 months Oil level in axis 2 gearbox Inspection Every 12 months Oil level in axis 3 gearbox Inspection Every 12 months Oil level in axis 4 gearbox Inspection Every 12 months Oil level in axis 5 6 gearbox Inspection Every 12 monthsi Robot harness Inspection Every 12 months Information labels Inspe...

Page 108: ...tion 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 v 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 1...

Page 109: ... to movement press tending very severe palletizing applications major use of axis 1 movement iv Depending on application the lifetime can vary The Service Information System SIS integrated in the robot software can be used as a guidance for planning service of gearbox for the individual robot This applies to gearboxes on axes 1 2 and 3 The lifetime of gearbox axes 4 5 and 6 is not calculated by SI...

Page 110: ... oil level can be inspected according to Inspecting the gearbox oil level in a floor mounted robot on page 111 The method described in this section of inspecting the oil level in a suspended robot is only valid for Other design than Type C and Type D Read more about design Type C and Type D in section Type C of IRB 4600 on page 374 and Type D of IRB 4600 on page 375 Required equipment Note Equipme...

Page 111: ...ion is shown in the figure Type C and Type D xx1200000632 Oil plug filling and inspection A Oil plug draining B Other design 1 than Type C and Type D xx0800000304 Oil plug inspection A Oil plug gearbox B Continues on next page Product manual IRB 4600 111 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 3 1 Inspecting oil level axis 1 gearbox Continued ...

Page 112: ...ubricants oil or grease on page 36 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 See Location of oil plugs floor mounted on page 111 Open the oil plug insp...

Page 113: ...l plug hole Required oil level 35 3 mm below the surface for the motor flange The oil level shall only just start to be ob served when looking through the oil filling hole See figure 6 Parts A 35 3 mm B Surface for motor flange C Filling hole D Oil level How to fill oil is described in section Changing the oil axis 1 gearbox on floor mounted robots on page 146 Add oil if required 7 Tightening torq...

Page 114: ...plug filling A Oil plug draining B Other design 2 than Type C and Type D A B C xx1000001436 Filling oil plug on gearbox A Draining oil plug on surface for motor flange B Surface for motor flange C Continues on next page 114 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 3 1 Inspecting oil level axis 1 gearbox Continued ...

Page 115: ...ox is filled with an amount of oil suited for an inverted position the oil level can only be inspected in the inverted position If the robot was taken down to stand on the floor the oil level would be above the oil plug hole which would result in oil leakage if the plug would be opened while robot stands on the floor Note Action WARNING Handling gearbox oil involves several safety risks see Gearbo...

Page 116: ... on page 146 Add oil if required 6 Tightening torque 3 8 Nm Refit the oil plug Note Only valid for Other design than Type C and Type D Before refitting the oil plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 7 116 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 3 1 Inspecti...

Page 117: ...washer gearbox See section Type of lubrication in gearboxes on page 144 Lubrication oil For article number see Spare part lists on page 391 Oil plug Quick connect fitting Content is defined in section Standard tools on page 385 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step...

Page 118: ...n the oil plug inspection location de pends on how the robot is mounted Note Always open the oil plug on top depending how the robot is mounted 4 Measure the oil level at the oil plug hole 5 Required oil level 42 mm 5 mm below the lower edge of the oil plug hole How to fill oil is described in section Changing the oil axis 2 gearbox on page 159 Add oil if required 6 Tightening torque 24 Nm Refit t...

Page 119: ...attachment The oil plug for inspection is shown in the figure Type C and Type D xx1200000633 Oil plug armhouse Not visible in this figure See enlarged figure A Oil plug armhouse B Continues on next page Product manual IRB 4600 119 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting the oil level axis 3 gearbox ...

Page 120: ...res may be required See references to these procedures in the step by step instructions below Inspecting the oil level axis 3 gearbox Use this procedure to inspect the oil level in the axis 3 gearbox Note Action WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 36 1 Move the robot to where the upper arm is placed in a 30 position 2 Continues on...

Page 121: ...ype C and Type D Open the oil plug armhouse 5 Measure the oil level at the oil plug hole 6 Required oil level oil in the gearbox shall be just below the edge of the oil plug hole How to fill oil is described in section Changing the oil axis 3 gearbox on page 163 Add oil if required 7 Tightening torque Other design than Type C and Type D in armhouse 10 Nm Other design than Type C and Type D in gear...

Page 122: ...quired Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting the oil level axis 4 gearbox Use this procedure to inspect the oil level in the axis 4 gearbox Note Action WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 36 1 Move the robot to where the upper arm points stra...

Page 123: ...4 See the figure in Location of axis 4 gearbox on page 122 Open the oil plug 5 Measure the oil level at the oil plug hole 6 Required oil level 35 5 mm below the oil plug flange How to fill oil is described in section Changing the oil axis 4 gearbox on page 169 Add oil if required 7 Tightening torque 10 Nm Refit the oil plug filling 8 Product manual IRB 4600 123 3HAC033453 001 Revision Y Copyright ...

Page 124: ...00000308 Oil plug tilthouse A Oil plug wrist also used as air inlet when draining from oil plug A B The figure shows IRB 4600 20 2 50 with wrist 12 20 kg xx0900000139 Oil plug tilthouse A Oil plug wrist also used as air inlet when draining from oil plug A B Continues on next page 124 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 3 5 I...

Page 125: ...rm is placed in its calibration position 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 3 CAUTION The gearbox can contain an excess of pres sure that can be hazardous Open the oil plug carefully in order to let out the excess pres sure 4 See the figure in Location of gearbox axes 5 6 on page 124 Open th...

Page 126: ... rotate axis 4 90 3 See the figure in Location of gearbox axes 5 6 on page 124 Note In this position it is not possible to open the oil plug tilthouse in order to level up oil in axes 5 and 6 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 4 CAUTION The gearbox can contain an excess of pres sure that can b...

Page 127: ...a 2 CAUTION The gearbox can contain an excess of pres sure that can be hazardous Open the oil plug carefully in order to let out the excess pres sure 3 See the figure in Location of gearbox axes 5 6 on page 124 Remove the oil plug wrist 4 Required oil level 3 3 mm from the lower edge of the oil plug in the wrist house Open the oil plug in the tilthouse to allow the oil level between axis 5 and 6 t...

Page 128: ...H Required equipment Note Equipment Content is defined in section Standard tools on page 385 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below See chapter Circuit diagram on page 393 Circuit diagram Continues on next page 128 Product manual IRB 4600 3HAC0334...

Page 129: ...ke an overall visual inspection of the cable harness in order to detect wear or damage 2 Check the connectors at the base 3 Check the connectors at the armhouse 4 Check all brackets and straps are properly attached to the robot 5 How to replace the cable harness is de scribed in Repair on page 187 Replace the cable harness if wear cracks or damage is detected 6 Product manual IRB 4600 129 3HAC0334...

Page 130: ...ol of flash A Warning Risk of tipping B Label Lifting instruction C Warning High temperature D Label Max air pressure E Warning Brake release unit F Label Calibration G AbsAcc Information Sign H UL Label J Oil quality K Continues on next page 130 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting information labels ...

Page 131: ...nt Note Spare part number Equipment See Spare part lists on page 391 Labels Inspecting labels Use this procedure to inspect the labels on the robot Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 Continues on next page Product manual IRB 4600 131 3HAC033453 001 Revision Y Copyright 2009 2021 ...

Page 132: ...formation labels on page 130 Check all labels 2 Replace any missing or damaged labels 3 132 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting information labels Continued ...

Page 133: ...t lists on page 391 Mechanical stop pin axis 1 Content is defined in section Standard tools on page 385 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Continues on next page Product manual IRB 4600 133 3HAC033453 001 Revision Y Copyright 2009 2021 ABB A...

Page 134: ...ed in any other way 2 How to replace the stop pin is described in section Replacing stop pin axis 1 on page 284 Note If the mechanical stop pin has been deformed or damaged all of its mounting parts have to be replaced xx0800000045 Parts A Attachment screws B Bracket C O ring 2 pcs Not used if bracket D is installed D Bracket E Stop pin 3 Check that the mechanical stop pin is prop erly attached 4 ...

Page 135: ...p pin can move freely in both directions and the bracket works as it is supposed to 5 Product manual IRB 4600 135 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the mechanical stop pin axis 1 Continued ...

Page 136: ...hanical stop Limited to 13 5 Type C and Type D 16 5 other design than Type C and Type D C Attachment screws D Washers E Required equipment Note Equipment etc Includes Stop Attachment screws plus washers Document for movable mechanical stop For spare part number see Spare part lists on page 391 Mechanical stop set axis 1 Content is defined in section Standard tools on page 385 Standard toolkit Cont...

Page 137: ...pressure supply to the robot before entering the robot work ing area 1 See the figure in Location of additional mechanical stops on page 136 Check the additional mechanical stops on axis 1 for damage 2 Tightening torque 82 Nm Make sure the stops are properly attached 3 Attachment screws M12x40 quality 8 8 A3F 2 pcs stop lug If any damage on stops or attachment screws etc is detected the mechanical...

Page 138: ...mper Content is defined in section Standard tools on page 385 Standard toolkit Inspecting dampers Use this procedure to inspect the dampers Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 Continues on next page 138 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All ...

Page 139: ...eck all dampers for existing impressions larger than 2 3 mm 3 Check attachment screws for deformation 4 If any damage is detected the damper must be replaced 5 Product manual IRB 4600 139 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting dampers Continued ...

Page 140: ...re to inspect the pressure relief valve Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 DANGER It is important to keep the pressure relief valve open and clean If the air pressure is stopped up too much pressure can be built up which can be hazardous 2 Continues on next page 140 Product manua...

Page 141: ...ontam inated or covered with litter 3 Clean if necessary Note Use a cloth or a brush 4 Product manual IRB 4600 141 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the pressure relief valve Continued ...

Page 142: ...d toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below 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 Note Action Check that the signal lamp is lit when motors are put in opera...

Page 143: ... the cable connections 5 24V Measure the voltage in connectors motor axis 3 6 Check the cabling If a fault is detected re place 7 Seal and paint the joints that have been opened Also repair possible damages of the special Foundry Prime paint coat of the robot See Cut the paint or surface on the robot be fore replacing parts on page 194 8 Product manual IRB 4600 143 3HAC033453 001 Revision Y Copyri...

Page 144: ...es available for registered users on myABB Business Portal www abb com myABB Note The type of oil pre filled in axis 4 gear differs from the type of oil recommended for field maintenance due to differences in factory and customer sites prerequisites The two types of oil are fully equal and compatible Use the type of oil specified in Technical reference manual Lubrication in gearboxes even though i...

Page 145: ...Used on the axes 1 and 2 gearboxes Nipple for quick connect fitting with o ring Other design than Type C and Type D Used on the axis 2 gearbox Used when the robot is fitted in a suspended position Not valid for type C and Type D Expansion container gearbox axis 1 valid for other design than Type C and Type D Product manual IRB 4600 145 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights r...

Page 146: ...d robot How to change the oil in a suspended robot see Changing the oil axis 1 gearbox on suspended robots on page 152 Location of oil plugs The axis 1 gearbox is located between the frame and base of the robot The oil plugs of the different types are shown in the figures Type C and Type D Note Only valid for Type C and Type D Oil plugs for filling and draining are not depending on in which positi...

Page 147: ... which position the robot is mounted Floor mounted Draining Oil plug on gearbox Filling Oil plug on surface for motor flange Mounted in suspended position Draining and filling Oil plug on surface for motor flange Continues on next page Product manual IRB 4600 147 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 4 2 Changing the oil axis 1 gearbox on floor mount...

Page 148: ...Oil plug draining A Oil plug filling B Surface for motor flange C Continues on next page 148 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 4 2 Changing the oil axis 1 gearbox on floor mounted robots Continued ...

Page 149: ...ox of oil Tip In order to save time a pneumatic oil dispenser can be used to suck out the oil from the gearbox Follow the instructions below Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 3...

Page 150: ...x 7 Using a low air pressure start sucking the oil out from the gearbox with the oil ejector equipment 8 Note Time consuming activity Only valid if an oil dispenser is not used If an oil dispenser is not used open the oil plug draining and drain oil into an oil collect ing vessel 9 WARNING Used oil is hazardous material and must be disposed of in a safe way See section De commissioning on page369 ...

Page 151: ... amount of oil in the gearbox is detailed in section Type of lubrication in gear boxes on page 144 Refill the gearbox with lubrication oil Note The exact amount of oil to be filled depends on the amount previously being drained 5 How to inspect the oil level is de scribed in section Inspecting oil level axis 1 gearbox on page 110 Inspect the oil level 6 Tightening torque 24 Nm Refit the oil plug N...

Page 152: ...ion is to fill the same amount of oil that was drained Measure the amount of oil that was drained and make a note of the result The same amount shall later be refilled Location of oil plugs The axis 1 gearbox is located between the frame and base of the robot The oil plugs are shown in the figures Other design than Type C and Type D Note Use correct oil plugs for filling and draining depending on ...

Page 153: ...1 Only valid for Other design than Type C and Type D Oil plug sealing washer gearbox See section Type of lubrication in gearboxes on page 144 Lubricating oil The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Continues on next page Product manual IRB 4600 153 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 4 ...

Page 154: ...gearbox Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 36 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the e...

Page 155: ...oil change equipment 8 WARNING Used oil is hazardous material and must be disposed of in a safe way See section De commissioning on page369 for more inform ation 9 Tip Make a note how much oil was drained The same amount shall later be refilled Let the oil drain until the gearbox is empty Note There will be some oil left in the gearbox after draining Measure the volume of the drained oil in the ve...

Page 156: ...sition Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 36 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug care fully in order to let out the e...

Page 157: ...n the protective hood on the oil plug 8 Tightening torque Other design than Type C and Type D 3 8 Nm Type C and Type D 24 Nm Refit the oil plug for venting Note Only valid for Other design than Type C and Type D Before refitting the oil plug in the gearbox al ways replace the oil plug sealing washer with a new one If not there is a risk of leakage 9 Expansion container axis 1 gearbox suspended mou...

Page 158: ...ery on the robot if ordered as option suspended inverted mounted If a floor mounted robot shall be fitted in a suspended mounted position an expansion container must be installed See Installing an expansion container on page 90 158 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 4 3 Changing the oil axis 1 gearbox on suspended robots Co...

Page 159: ... Information about the oil is found in Technical reference manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page 144 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel To be fitted on a hose and then used for draining connected to the quick connect fit ting Nipple TEMA IF 3820 S06 See Location of oil plug...

Page 160: ...9 Either connect a nipple to the quick connect fitting in the hole for draining or remove the quick connect fitting 4 See the figure in Location of oil plugs on page 159 Note Drainage will be quicker if the oil plug filling is removed Open the oil plug filling 5 Note Draining is time consuming Elapsed time varies depending on the temperature of the oil Drain the gearbox oil using an oil collecting...

Page 161: ...RNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 36 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 See the figure in Location of oil plugs on page 159 Open oil plug filling 4 Where to find type of oil and total amount is detailed in Type and amo...

Page 162: ...efit oil plug Note Only valid for Other design than Type C and Type D Before refitting the oil plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 7 162 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 4 4 Changing the oil axis 2 gearbox Continued ...

Page 163: ...nal center Oil plugs are shown in the figure Type C and Type D xx1200000633 Oil plug armhouse not visible in this figure A Oil plug armhouse B Continues on next page Product manual IRB 4600 163 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 4 5 Changing the oil axis 3 gearbox ...

Page 164: ...page 144 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 144 Oil dispenser xx1200000862 Funnel Content is defined in section Standard tools on page 385 Standard toolkit Continues on next page 164 Product manual IRB 4600 3HAC033453 001 Revision Y Copyr...

Page 165: ...box lubricants oil or grease on page 36 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug care fully in order to let out the excess pressure 4 See the figure in Location of oil plugs on page163 Open the oil plug armhouse 5 See the figure in Location of oil plugs on page163 Type C and Type D Open the other oil plug in the armhouse and use it as a ventil...

Page 166: ... Move the upper arm of the robot to a position where the oil plug gearbox is pointing at the floor 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug care fully in order to let out the excess pressure 3 An example...

Page 167: ...aterial and must be disposed of in a proper way See section De commissioning for more information 9 Note There will be some oil left in the gearbox after draining 10 See the figure in Location of oil plugs on page163 Tightening torque Refit the oilplugs 11 Other design than Type C and Type D in armhouse 10 Nm Other design than Type C and Type D in gearbox 3 Nm Type C and Type D both plugs 10 Nm Fi...

Page 168: ...o find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 144 Refill the gearbox with lubricating oil Tip Use a funnel 6 Note The amount of oil to be filled depends on the amount previously being drained How to inspect oil is described in section Inspecting the oil level axis 3 gearbox on page 119 Inspect the oil level 7 Tightening torque Refit the oil plug 8 O...

Page 169: ...box see section Type of lubrication in gear boxes on page 144 Lubricating oil The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Used for venting the gearbox during draining A suitable hose would be a hose normally used for compressed air Plastic hose Length minimum 300 mm Diameter 5 mm xx1200000862 Funnel Continues on next page Product manual IR...

Page 170: ...before entering the robot working area 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 36 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 4 See the figure in Location of oil plugs on page 169 Open oil plug draining 5 Continues on next page 170...

Page 171: ...ee section De commissioning on page369 for more inform ation 7 Tightening torque 10 Nm Refit the oil plug 8 Filling oil Use this procedure to fill oil in the gearbox Note Action xx0800000330 Move the upper arm to the position shown in the figure 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Continues ...

Page 172: ...il plugs on page 169 Open the oil plug filling 5 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 144 Refill the gearbox with lubricating oil Tip Use a funnel 6 Note The amount of oil to be filled depends on the amount previously being drained Tightening torque 10 Nm Refit the oil plug 7 172 Product manual IRB 4600 3HAC033453 001 Revision Y Copy...

Page 173: ...n in the figure The figure shows wrist variant 60 kg A B xx0800000308 Oil plug tilthouse A Oil plug wrist unit also used as air inlet when draining from oil plug A B Continues on next page Product manual IRB 4600 173 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 4 7 Changing oil axes 5 and 6 gearboxes ...

Page 174: ...icient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard tools on page 385 Standard toolkit Draining axes 5 and 6 gearbox wrist 60 kg Use this procedure to drain oil from the gearbox CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the excess pressure Note Action Move the upper ...

Page 175: ...plugs on page 173 Open the oil plug wrist air inlet This is done for the ventilation of the gear box and to fascilitate draining 7 Note Draining is time consuming Elapsed time varies depending on the temperature of the oil Drain the gearbox 8 WARNING Used oil is hazardous material and must be disposed of in a safe way See section De commissioning on page369 for more inform ation 9 Draining axes 5 ...

Page 176: ...8 Filling oil axes 5 and 6 gearbox wrist 60 kg Use this procedure to fill oil in the gearbox CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the excess pressure Note Action See the figure in Location of oil plugs on page 173 Move the upper arm to a position where the oil plug wrist points upwards 1 See the figure in Locati...

Page 177: ...ation oil Note The amount of oil to be filled depends on the amount previously being drained 8 How to inspect the oil level is described in section Inspecting oil level gearbox axes 5 6 on page 124 Inspect the oil level 9 Tightening torque 10 Nm Refit both oil plugs 10 Filling oil axes 5 and 6 gearbox wrist 12 20 kg Use this procedure to fill oil in the gearbox CAUTION The gearbox can contain an e...

Page 178: ...ith lubrication oil Note The amount of oil to be filled depends on the amount previously being drained 6 How to inspect the oil level is described in section Inspecting oil level gearbox axes 5 6 on page 124 Inspect the oil level 7 Note If the robot is fitted in a suspended position the wrist should be turned 180 8 Tightening torque 10 Nm Refit the oil plugs 9 178 Product manual IRB 4600 3HAC03345...

Page 179: ...tery 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 FlexPendant for instructions WARNING See Hazards related ...

Page 180: ...x0800000322 SMB battery 2 pole battery contact A Battery cover B Attachment screws C SMB battery cable D How to arrange the battery cable E Continues on next page 180 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 4 8 Replacing SMB battery Continued ...

Page 181: ...ttery includes protection circuits Replace it only with given spare part no or an ABB approved equivalent SMB battery pack See Spare part lists on page 391 Content is defined in section Standard tools on page 385 Standard toolkit See chapter Circuit diagram on page 393 Circuit diagram Removing SMB battery Use this procedure to remove the SMB battery Note Action This is done in order to facilitate ...

Page 182: ...ure in Location of SMB battery on page 180 Disconnect the battery cable and remove the bat tery 6 How to dispose of the used SMB battery see chapter Decommissioning on page 369 7 Refitting SMB battery Use this procedure to refit the SMB battery Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 E...

Page 183: ...B battery on page 180 Secure the SMB cover with its attachment screws 5 Detailed in Updating revolution counters on page 344 Update the revolution counter 6 DANGER Make sure all safety requirements are met when performing the first test run 7 Product manual IRB 4600 183 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 4 8 Replacing SMB battery Continued ...

Page 184: ...ations see Inspection activities on page 110 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 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 A...

Page 185: ...r cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI 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 Prim...

Page 186: ...ooling fans Inspect the air supply inlet of the the motor cooling fans Clean to remove any contamination that could hinder the air supply 186 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 3 Maintenance 3 5 1 Cleaning the IRB 4600 Continued ...

Page 187: ...d 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 21 before commencing any service work Note If the IRB 4600 is connected to power always make sure that the IRB 4600 is connected to protective earth and a re...

Page 188: ...he pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no...

Page 189: ...exposed to any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually ...

Page 190: ...arted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 190 Product manual IRB 4...

Page 191: ...ction Check the sealing to ensure that The sealing is of the correct type There is no damage on the main lip 1 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 2 Article number is specified in Equipment on page 191 A B C xx2000000071 A ...

Page 192: ...d because leakage could occur Clean the surfaces properly in accordance with the recommendations of ABB 2 Distribute the sealing compound evenly over the surface preferably with a brush 3 Tighten the screws evenly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damag...

Page 193: ...ontamination Lubricate the o ring with grease 4 Tighten the screws evenly while assembling 5 Check that the o ring is not squashed outside the o ring groove 6 Product manual IRB 4600 193 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 2 3 Mounting instructions for sealings Continued ...

Page 194: ...int Standard Foundry Plus ABB Orange 3HAC037052 001 Touch up paint Standard Foundry Plus Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 194 Product manual IRB 4600 3HAC033453 001 Revision Y Cop...

Page 195: ...e to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jam...

Page 196: ...ing the complete cable harness consists of the following parts presented in the order the work is recommended to be performed Removal in the base Removing cable harness in base on page 199 Removal in the frame Removing cable harness in frame on page 205 Removal in lower arm and armhouse Removing cable harness in lower arm and armhouse on page 206 How to replace the SMB unit brake release unit and ...

Page 197: ...harness base and frame xx0900000009 Cover base A Bracket B Cable harness C Axis 1 motor cable D Axis 2 motor cable E Axis 2 motor F Axis 1 motor G Continues on next page Product manual IRB 4600 197 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 198: ... 30 mm Deep well hexagon socket Content is defined in section Standard tools on page 385 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below Continues on next page 198 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserv...

Page 199: ...t Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 349 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the...

Page 200: ...ver base has been removed 3 Parts A R1 CP CS B R1 MP C Air hose connector D Position of R1 ETHERNET if used E R1 SMB A B C xx0800000456 A Base B Cover base C Attachment screws Remove the cover base 4 Disconnect connectors on the brake release unit X8 X9 X10 5 Continues on next page 200 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 1 Remo...

Page 201: ...hin nut securing the R1 SMB connector on the outside of the bracket Tip Use a deep well hexagon socket width 30 mm like the ones used for spark plugs or similar xx1200000888 8 Unscrew the nut for the air connection on the inside of the bracket 9 Continues on next page Product manual IRB 4600 201 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 1 Removing the compl...

Page 202: ...en performing this procedure in order not to damage cables or other components 11 Parts A Bracket at a 90 angle B Base A B C D xx1200000890 A R1 CP CS B R1 MP C Air hose connector D R1 SMB Remove connectors and air hose connector completely from the bracket R1 CP CS R1 MP R1 SMB Air hose connector R1 ETHERNET if used 12 How to remove the SMB unit is described in section Removing the SMB unit on pa...

Page 203: ...ections of R1 SMB1 2 R1 SMB2 6 15 Parts A Screen connection 4 pcs xx0900000015 Disconnect the earth cables 16 Parts A Earth B Distance screws Continues on next page Product manual IRB 4600 203 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 204: ...et securing the cable package inside the base on the left side by following these steps Unscrew the attachment screws just enough to be able to remove the bracket Lift the bracket off the screws 18 Parts A Base B Attachment screws C Bracket How to remove the cable package from the frame is described in section Removing cable harness in frame on page 205 Continue removal of the cable package from t...

Page 205: ... Remove the bracket securing the cable package to the frame 3 See the figure in Location of the cable harness on page 197 Cut the cable straps securing the cable harness to the frame and lower arm 4 A C E F B D xx1200000886 A Tape B Connectors to SMB unit and Brake release unit C R1 CP CS D Air hose E R1 MP F R1 SMB Connector bent and taped upwards Prepare the end of the cable package in the base ...

Page 206: ...le harness in the lower arm and armhouse Tip Before starting this procedure first remove the cable harness in the base Removing the complete cable harness on page 196 and frame Removing the complete cable harness on page 196 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 See the figure in Loc...

Page 207: ...ket armhouse D Cable bracket xx0800000335 Remove the bracket on the armhouse 4 Parts A Tubular shaft unit B Attachment screws C Bracket armhouse Continues on next page Product manual IRB 4600 207 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 208: ...bles from the axis 3 axis 4 axis 5 and axis 6 motors see section Removing motors on page 287 Continue the removal of the cable package by disconnecting the motor cables of the axis 3 axis 4 axis 5 and axis 6 motors 7 208 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 209: ...consists of the following parts presented in the order the work is recommended to be performed Refitting in the frame Refitting the cable harness in the frame on page 212 Refitting in the base Refitting the cable harness in the base on page 215 Refitting in the lower arm and armhouse Refitting the cable harness in the lower arm and armhouse on page 221 How to refit the SMB unit brake release unit ...

Page 210: ...arness base and frame xx0900000009 Cover base A Bracket B Cable harness C Axis 1 motor cable D Axis 2 motor cable E Axis 2 motor F Axis 1 motor G Continues on next page 210 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continued ...

Page 211: ...on socket Content is defined in section Standard tools on page 385 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below 3HAC042536 001 Shell Gadus S2 Cable grease Continues on next page Product manual IRB 4600 211 3HAC033453 001 Revision Y Copyright 2009 2021 ...

Page 212: ...and base are presented below Chose one of the methods 3 A C E F B D xx1200000886 A Tape B Connectors to SMB unit and Brake release unit C R1 CP CS D Air hose E R1 MP F R1 SMB Connector bent and taped upwards Use this procedure when replacing the old cable harness Method 1 step 1 Prepare the end of the cable package in the base with tape as shown in the figure Tip In order to protect the connectors...

Page 213: ...orming this procedure in order not to damage cables or other components Tip In order to protect the connectors from get ting residual grease on the cable harness put some plastic over them prior to pushing it through the hole in the frame Note Check that cables and air hose are placed as shown in the figure above Use this procedure when fitting a new cable harness Without removing the plastic arou...

Page 214: ...0016 Secure the cover to the frame with its attach ment screws 9 Parts A Frame B Hole in frame C Cover How to refit the motor cables is described in section Refitting motors on page 295 Connect the axis 1 and axis 2 motor cables 10 Continues on next page 214 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable har...

Page 215: ...he cable harness in the base 12 Refitting the cable harness in the base Use this procedure to refit the cable harness in the base Tip Before starting this procedure first refit the cable harness in the frame See Refitting the complete cable harness on page 209 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe g...

Page 216: ...e harness xx0900000098 Valid for other design than Type C and Type D Attach the cable harness to the bracket 3 Parts A Attachment screw and nut B Bracket C Cable harness Continues on next page 216 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continued ...

Page 217: ... bracket on the attachment screws Secure the bracket with its attach ment screws 4 Parts A Base B Attachment screws 2 pcs C Bracket xx0900000015 Refit the earth cables 5 Parts A Earth B Distance screws Connect the contacts on the SMB unit R1 SMB1 2 R1 SMB3 6 R2 SMB 6 How to refit the SMB unit is described in section Refitting the SMB unit on page 229 Refit the SMB unit 7 Continues on next page Pro...

Page 218: ... at a 90 angle 9 Parts A Bracket B Base A B C xx1200000857 A R1 CP CS B R1 MP C Air hose Before refitting the connectors on the bracket arrange cables and connectors as shown in the figure 10 Continues on next page 218 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continued ...

Page 219: ...A Earth cables B R1 SMB1 2 C R1 SMB3 6 D R2 SMB E R1 CP CS F R1 MP G Air hose H Position of R1 ETHERNET if used J R1 SMB A B C D xx1200000887 A Base B Distance screw C Attachment screw D Bracket Secure the bracket on the distance screws 12 Reconnect connectors on the brake release unit X8 X9 X10 13 Continues on next page Product manual IRB 4600 219 3HAC033453 001 Revision Y Copyright 2009 2021 ABB...

Page 220: ...milar xx1200000888 14 Refit the air hose connector on the bracket Note Check that there is no leakage from the air hose 15 Reconnect the battery cable 16 xx0900000099 Secure the battery cable with cable straps 17 Parts A Cable straps 2 pcs Continues on next page 220 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete c...

Page 221: ... on the lower arm and armhouse is described in section Refitting the cable harness in the lower arm and armhouse on page 221 Continue the refitting of the cable package on lower arm and armhouse 22 Refitting the cable harness in the lower arm and armhouse Use this procedure to refit the cable harness in the lower arm and armhouse Tip Before starting this procedure first refit the cable harness in ...

Page 222: ...B Bracket lower arm C Bracket armhouse D Cable bracket See the figure in Location of the cable harness on page210 Cable harness lower arm Refit the cable straps securing the cable harness to the lower arm 3 Push the cable harness carefully into the armhouse 4 Continues on next page 222 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 2 Refi...

Page 223: ...otors on page 295 Reconnect the axis 3 axis 4 axis 5 and axis 6 motor cables 7 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 8 Axis Calibration is described in Calibrating with Axis Calibration method on page348 General calibration information is included in section Calibration on page 335 Continues on next pag...

Page 224: ... a vital part for the stability of the robot 9 DANGER Make sure all safety requirements are met when performing the first test run 10 224 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continued ...

Page 225: ...e There are different variants of SMB units and batteries The variant with the 3 pole battery contact RMU 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 Note Equipment Content is defined in section Standard tools on page 385 Standard toolkit Continues on next page Product m...

Page 226: ...s reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 349 If no previous reference values exist and no new reference values can be c...

Page 227: ...cs Cut the cable straps securing the battery cable 4 xx0900000100 Remove the screw that secures the bracket and unscrew the three other screws a little just enough to be able to slide the bracket sideways Note It is not needed to remove these three screws 5 Parts A Screw to be removed B Screws to be unscrewed a little 3 pcs Continues on next page Product manual IRB 4600 227 3HAC033453 001 Revision...

Page 228: ...ct cable clamps 7 Parts A Cable clamps See the figure in Location of SMB unit on page 225 Unscrew the attachment screws securing the SMB unit just enough to be able to re move the SMB unit 8 Remove the SMB unit 9 xx1700000993 Disconnect the battery cable by pressing down the upper lip of the R1 G connector to release the lock while pulling the connect or upwards 10 See the figure in Location of SM...

Page 229: ...n Location of SMB unit on page 225 Place the SMB unit on its attachment screws 3 Secure the SMB unit with its attachment screws 4 A xx0900000035 Refit the cable clamps 5 Parts A Cable clamps See the figure in Location of SMB unit on page 225 Put back the cable harness in the base and refit the bracket on the distance screws Note Use caution when performing this procedure order not to damage cables...

Page 230: ...tion is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 10 Axis Calibration is described in Calibrating with Axis Calibration method on page348 General calibration information is included in section Calibration on page 335 DANGER Make sure all safety requirements are met when performing the first test run 11 230 Product manual IRB 4600 ...

Page 231: ...1 Brake release board A Connectors on push button board The connectors X8 X9 and X10 are placed on the push button board as shown in the figure below X9 X8 X10 xx1700000978 Continues on next page Product manual IRB 4600 231 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 4 Replacing the brake release board ...

Page 232: ...manual spare parts IRB 4600 Includes brake release board and harness Removing the brake release board Use this procedure to remove the brake release board Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the ...

Page 233: ...X10 xx1700000978 Disconnect connectors X8 X9 and X10 from the brake release board 6 Remove the nuts securing the brake release board 7 Remove the brake release board 8 Refitting the brake release board Use this procedure to refit the brake release board Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working...

Page 234: ...wn properly 4 Verify that the robot cabling is positioned correctly according to previously taken pic ture 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 5 A B C xx0800000456 Use caution when pushing the base cover into position while at the same time checking t...

Page 235: ...to the SMB cover 9 Press the push buttons 1 to 6 one at a time to make sure that the buttons are moving freely and do not stay in any locked position 10 DANGER Make sure all safety requirements are met when performing the first test run 11 Product manual IRB 4600 235 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 4 Replacing the brake release board Continued ...

Page 236: ...ame B Lower arm C Arm house part of complete upper arm D Tubular shaft unit part of complete upper arm E Wrist unit part of complete upper arm F Required equipment Note Article number Equipment Length 2 m 2 pcs 1 5 m 1 pcs Roundslings Lifting capacity 1 000 kg 3 pcs 3HAC15535 1 Support legs Always use guide pins in pairs 3HAC15520 2 Guide pin M8x150 Continues on next page 236 Product manual IRB 46...

Page 237: ...FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Refe...

Page 238: ... varies depending on the tem perature of the oil 4 How to remove the cable harness in base and frame is detailed in sections Removing cable harness in base on page 199 Removing cable harness in frame on page 205 Removing cable harness in lower arm and armhouse on page 206 Remove the cable harness in the base the frame and the lower arm of the robot Tip Wrap up the cabling against the frame to keep...

Page 239: ...to the foundation 8 xx1800000874 Lift the robot and fit three support legs to the robot base using bolts washers and nuts DANGER Working underneath the manipulator without safely securing the support legs between the robot base and the foundation will result in serious or fatal injury Make sure the robot is stable and safely secured to the foundation via the support legs before working underneath ...

Page 240: ... the foundation using bolts and washers 10 xx1800000879 Remove the cover plate at the bottom of the base 11 Continues on next page 240 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 5 Replacing the base Continued ...

Page 241: ...lity Steel 12 9 Gleitmo and washers 24 24 pcs C Type C and Type D Attachment screws M12x50 quality Steel 12 9 Gleitmo and washers 24 24 pcs D O ring Not visible behind cover plate in figure of Type C and Type D E Cover plate F Attachment screws M6x16 qual ity 8 8 A2F 5 pcs Continues on next page Product manual IRB 4600 241 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Rep...

Page 242: ...he guide pins if the arm system is about to be laid down on the floor See Illustration of robot put down on its side on page 309 15 CAUTION The weight of the base is 49 kg All lifting accessories used must be sized accordingly 16 Lifting eye M8 xx1800000931 Fit three lifting eyes to the base and secure with roundslings in an overhead crane or similar 17 Continues on next page 242 Product manual IR...

Page 243: ...ing eye M8 Fit three lifting eyes to the base and secure with roundslings in an overhead crane or similar 2 xx1800000885 Fit the new base to the support legs and secure with the attachment screws 3 Tip Use Loctite 7063 or similar for cleaning Remove residues of old Loctite and other contaminations from surfaces before apply ing new Loctite 574 4 Continues on next page Product manual IRB 4600 243 3...

Page 244: ...box weighs 380 kg together All lifting accessories must be sized accord ingly 6 Lift the arm system to the mounting site 7 Guide pin M8x150 3HAC15520 2 Fit two guide pins in opposite holes in the axis 1 gearbox 8 Always use guide pins in pairs xx1800000932 Continues on next page 244 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 3 5 Replaci...

Page 245: ...ype C and Type D Attachment screws M8x40 quality Steel 12 9 Gleitmo and washers 24 24 pcs C Type C and Type D Attachment screws M12x50 quality Steel 12 9 Gleitmo and washers 24 24 pcs D O ring Not visible behind cover plate in figure of Type C and Type D E Cover plate F Attachment screws M6x16 qual ity 8 8 A2F 5 pcs Apply some grease to the o ring and refit the o ring between the cover and base 10...

Page 246: ...ecuring the robot on page 61 Lower the robot and secure it to the found ation 14 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 15 Axis Calibration is described in Calibrating with Axis Calibration method on page348 General calibration information is included in section Calibration on page 335 DANGER Make sure a...

Page 247: ...ted as shown in the figure xx1200000635 Upper arm A Lower arm B Washer 3 pcs xx1200000520 C Attachment screws M10x40 quality steel 12 9 Gleitmo 15 pcs D Axis 3 gearbox E Continues on next page Product manual IRB 4600 247 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing the complete upper arm ...

Page 248: ...box E Required equipment Note Equipment For spare parts no see Spare parts Upper arm 2 05 2 50 2 55 in Product manual spare parts IRB 2600 Armhouse For spare parts no see Spare parts Upper arm 2 05 2 50 2 55 in Product manual spare parts IRB 2600 Tubular shaft unit Continues on next page 248 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 4 ...

Page 249: ...tandard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these proced ures in the step by step instructions be low Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to beginning the repair wor...

Page 250: ...e calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the complete upper arm Use this procedure to remove the complete upper arm This procedure can be done without draining the axis 3 gearbox Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 xx0800000336 Run the robo...

Page 251: ...ssure supply to the robot before entering the robot working area 7 How to disconnect cables from motors is detailed in sections Removing motors on page 287 Disconnect all motor cables from motors axes 3 4 5 and 6 8 xx0800000335 Remove the bracket fitted on the tubular shaft unit 9 Parts A Tubular shaft unit B Attachment screws M6x16 qual ity 8 8 A2F 2 pcs C Bracket Remove the signal lamp if used 1...

Page 252: ...e Remove the attachment screws securing the upper arm to the lower arm 13 Remove the complete upper arm 14 Attaching the lifting accessories to the upper arm Attaching the lifting accessories Note Action Dimension is specified in Required equipment on page 248 xx1100000568 Fit two screws in the wrist unit The purpose of these screws is to prevent the roundsling from sliding 1 Continues on next pag...

Page 253: ...roundsling through each rotating lifting point and fasten both ends at the lifting hook 3 See figure Attaching the roundslings to the upper arm on page 254 Dimension is specified in Required equipment on page 248 Make a loop of the third round sling running it around the wrist unit Run the roundsling on both sides of the screws and fasten the free end of the roundsling to the lifting hook 4 See fi...

Page 254: ... Length 1 5 m D Refitting the complete upper arm Use this procedure to refit the complete upper arm Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 254 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 4 1 Replacing ...

Page 255: ... D 35 Nm Tightening torque and angle Type C and Type D 50 Nm and 90 angle Refit the upper arm to the lower arm with its attachment screws Note Use new attachment screws It may be necessary to turn the gear by ro tating the motor pinion with a rotation tool motor beneath the motor cover 8 xx0800000338 Using caution push the cable package through the hole where the cable bracket will be fitted 9 Par...

Page 256: ... enclosed with the calibration tools Recalibrate the robot 14 Axis Calibration is described in Calibrating with Axis Calibration method on page348 General calibration information is included in section Calibration on page 335 DANGER Make sure all safety requirements are met when performing the first test run 15 256 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All right...

Page 257: ...2 50 2 55 in Product manual spare parts IRB 2600 Tubular shaft unit 2 pcs Dimension M8 Guide pins Isopropanol Cleaning agent Loctite 574 Sealing liquid Content is defined in section Standard tools on page 385 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these proced ures in the step by step instructions be ...

Page 258: ...bility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 349 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine...

Page 259: ...d in the continued removal procedure 6 How to remove motors is described in section Removing motors on page 287 Remove motors axes 4 5 and 6 7 How to remove the wrist unit is detailed in section Removal of wrist unit on page 265 Tip If only the tubular shaft unit shall be re placed it is a good idea to remove the wrist unit at this stage 8 CAUTION The robot arm tube weighs 65 kg All lifting access...

Page 260: ...g complete tubular shaft unit on page 257 Remove the tubular shaft unit using caution The tubular shaft unit is fitted with Loctite CAUTION Do not damage the gears when removing the tubular shaft unit 12 CAUTION Remaining oil will drain out from the gear box cavity when the tubular shaft is lifted out Refitting complete tubular shaft unit Use this procedure to refit the tubular shaft unit Note Act...

Page 261: ...can be fitted to the lower attachment hole for the cable bracket removed in a previous step The plate should be fitted so it points down wards and functions as a mechanical stop for the roundsling At the other end of the tubular shaft unit a shackle can be fitted if the wrist unit is re moved 5 Specified in Required equipment on page 257 Fit guide pins in the upper arm house 6 Note There are two p...

Page 262: ...tting of wrist unit on page 266 If the wrist unit has been removed from the tubular shaft unit refit it now 12 How to refill oil in gearbox is described in section Changing the oil axis 4 gearbox on page 169 Refill gearbox axis 4 with oil 13 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 14 Axis Calibration is d...

Page 263: ...r B O ring sealing plate C Wrist unit D Spring washer conical 8 4x18x2 quality steel mZn12c 7 pcs E Attachment screw M8x40 quality steel 12 9 Gleitmo 7 pcs F Guide pin G only available for robots that are calibrated with Axis Calibration Continues on next page Product manual IRB 4600 263 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 4 3 Replacing wrist unit ...

Page 264: ...ity steel 12 9 Gleitmo 5 pcs B Spring washer conical 8 4x18x2 quality steel mZn12c 5 pcs C Gears D Wrist unit E O ring Placed on the wrist not visible Sealing lower image F Guide pin only available for robots that are calibrated with Axis Calibration G Continues on next page 264 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 4 3 Replacing w...

Page 265: ...om the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possib...

Page 266: ...t be sized ac cordingly 4 Secure the wrist unit with a roundsling in an overhead crane or similar 5 See the figure in Location of wrist unit on page 263 Remove the attachment screws and carefully remove the wrist unit CAUTION Do not damage the gears 6 Refitting of wrist unit Use this procedure to refit the wrist unit Note Action DANGER Turn off all electric power supply hydraulic pressure supply a...

Page 267: ... upper arm tube The hole is available on robots that are calib rated with the Axis Calibration method 2 Continues on next page Product manual IRB 4600 267 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 4 3 Replacing wrist unit Continued ...

Page 268: ...ffected negatively 3 Verify that the parallel pin sticks out from the wrist according to the meas urement given below IRB 4600 60 2 05 45 2 05 40 2 55 6 0 5 xx1600000702 IRB 4600 20 2 50 4 0 0 5 xx1600000703 Clean all assembly surfaces 4 Remove any painting from the assembly sur faces with a knife Continues on next page 268 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB ...

Page 269: ...pper arm CAUTION Do not damage the gears 9 CAUTION Make sure that the o ring stays in place on the wrist unit xx1000000223 Adjust the play of the wrist by following these steps Fit the measuring tool at the rear of the motor Push the wrist as shown in the figure to locate the smallest play in the same way as for adjustment of motors for axes 4 5 and 6 See Refitting motors on page295 10 Parts A Gea...

Page 270: ...age 173 Refill oil in gearbox axes 5 6 14 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Re calibrate the robot 15 Axis Calibration is described in Calib rating with Axis Calibration method on page 348 General calibration information is in cluded in section Calibration on page 335 DANGER Make sure all safety requirements are met when...

Page 271: ...ocedures may be required See references to these procedures in the step by step instructions below Measurement axis 5 The procedure below details how to measure the play of axis 5 Note The measuring tool and measuring values differ depending on robot version Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the r...

Page 272: ...asuring tool play B 140 mm C 85 mm F 40N Remove the load and set the dial indicator to zero 5 xx0300000187 Apply load F in the opposite direction as shown in the figure to the right 6 Values for IRB 4600 60 2 05 45 2 05 40 2 55 A Measuring tool play B 207 5 mm C 135 mm F 90N Values for IRB 4600 20 2 50 A Measuring tool play B 140 mm C 85 mm F 40N Continues on next page 272 Product manual IRB 4600 ...

Page 273: ...r robot version IRB 4600 60 2 05 45 2 05 40 2 55 0 10 mm IRB 4600 20 2 50 0 08 mm Remove the load and measure the play by reading the dial indicator 7 Product manual IRB 4600 273 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 4 4 Measuring the play axis 5 Continued ...

Page 274: ...s re quired Other tools and procedures may be required See references to these procedures in the step by step instructions below Measurement axis 6 The procedure below details how to measure the play in axis 6 Note The measuring tool and measuring values differ depending on robot version Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to t...

Page 275: ...ng tool play B 140 mm m 10 kg xx0300000189 Apply load F in one direction Note Different load and distances for the differ ent robot versions as specified to the right 4 Values for robot versions IRB 4600 60 2 05 45 2 05 40 2 55 A Measuring tool play B 100 mm C 100 mm F 50N Values for robot version IRB 4600 20 2 50 A Measuring tool play B 100 mm C 150 mm F 40N Remove the load and set the dial indic...

Page 276: ...00 20 2 50 A Measuring tool play B 100 mm C 150 mm F 40N The maximum play allowed at the given distance B from the center of axis 6 is for robot version IRB 4600 60 2 05 45 2 05 40 2 55 0 16 mm Values for IRB 4600 20 2 55 0 19 mm Remove the load and measure the play by reading the dial indicator 7 276 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 R...

Page 277: ...Type C and Type D The lower arm is located as shown in the figure xx1200000636 Upper arm A Axis 3 gearbox B Continues on next page Product manual IRB 4600 277 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the lower arm ...

Page 278: ...rews M12x50 quality Steel 12 9 Gleitmo 18 pcs J Other design than Type C and Type D The lower arm is located as shown in the figure A B C D E F G H J xx0800000360 Upper arm A Axis 3 gearbox B Lower arm C Continues on next page 278 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 5 1 Replacing the lower arm Continued ...

Page 279: ...e to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibrati...

Page 280: ...emove the cable package in frame lower arm and armhouse is de scribed in sections Removing cable harness in frame on page 205 Removing cable harness in lower arm and armhouse on page 206 Remove the cable package from all axes except in the base 4 Secure the upper arm with a roundsling in an overhead crane 5 How to remove the complete upper arm is described in section Removing the complete upper ar...

Page 281: ...tachment screws and wash ers that secure the lower arm to the axis 2 gearbox 9 Remove the lower arm 10 Refitting the lower arm Use this procedure to refit the lower arm Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page Product manual IRB 4600 281 3HAC033453 001 Revision Y ...

Page 282: ...rane and lift it to the robot 4 Attachment screws M12x50 quality steel Gleitmo 12 9 18 pcs Refit the attachment screws and washers to secure the lower arm to the axis 2 gear box 5 Tightening torque 110 Nm xx1800000935 Secure the complete upper arm with round slings in an overhead crane and lift it to the robot 6 How to refit the complete upper arm is described in section Refitting the complete upp...

Page 283: ...ating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 9 Axis Calibration is described in Calibrat ing with Axis Calibration method on page 348 General calibration information is included in section Calibration on page 335 DANGER Make sure all safety requirements are met when performing the first test run 10 Product manual IRB 4600 283 3HAC033453 001 Revision Y...

Page 284: ...sed if bracket D is installed C Bracket D Stop pin E Required equipment Note Equipment For spare parts number see Spare parts Frame and base in Product manual spare parts IRB 2600 Stop pin Content is defined in section Standard tools on page 385 Standard toolkit Continues on next page 284 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 6 1 R...

Page 285: ...hment screws securing the bracket and stop pin 2 See the figure in Location of stop pin axis 1 on page 284 Remove the bracket and stop pin 3 Refitting the stop pin axis 1 Use this procedure to refit the stop pin axis 1 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 See the figure in Location ...

Page 286: ... 243 Secure the stop pin together with bracket D on the frame with its attachment screws Use Locking liquid 4 Tightening torque 10 Nm See the figure in Location of stop pin axis 1 on page 284 DANGER Make sure all safety requirements are met when performing the first test run 5 286 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 6 1 Replacing...

Page 287: ...5x16 quality Steel 8 A2F 7 pcs A Motor cover B Attachment screws axis 1 motor 4 pcs washers See Tightening torques and attachment screws on page 299 C Attachment screws axis 2 motor 4 pcs washers See Tightening torques and attachment screws on page 299 C Connection box D Axis 1 motor E Axis 2 motor E O ring F Hole G Cable gland cover H Continues on next page Product manual IRB 4600 287 3HAC033453 ...

Page 288: ...crews axis 3 motor 4 pcs washers See Tightening torques and attachment screws on page 299 B Attachment screws axis 4 axis 5 and axis 6 motors 3x4 pcs washers Tightening torques and attachment screws on page 299 B Axis 3 motor C Axis 4 motor D Axis 5 motor E Axis 6 motor F O ring axis 4 axis 5 and axis 6 G Armhouse H Continues on next page 288 Product manual IRB 4600 3HAC033453 001 Revision Y Copyr...

Page 289: ... required Other tools and procedures may be required See references to these procedures in the step by step instructions below Weights The motors for the different axes weighs according to the table Weight in kg Motor 13 kg Axis 1 motor 25 kg Axis 2 motor 13 kg Axis 3 motor 8 kg Axis 4 motor 8 kg Axis 5 motor 8 kg Axis 6 motor Continues on next page Product manual IRB 4600 289 3HAC033453 001 Revis...

Page 290: ... calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 349 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Ca...

Page 291: ...n Changing the oil axis 2 gearbox on page 159 Axis 2 motor The gearbox has to be drained before removing the motor 2 How to drain the gearbox is described in section Changing the oil axis 3 gearbox on page 163 Axis 3 motor The gearbox has to be drained before removing the motor 3 Axis 4 axis 5 and axis 6 motors Draining of gearbox oil is not needed if robot is positioned as recommended 4 Removing ...

Page 292: ...robot 5 Parts A Cover B Attachment screws 10 pcs washers How to remove the fan is detailed in section Installation of cooling fan for motors option on page 82 Only applicable to motors on axes 1 and 2 with fan fitted Remove the fan before starting the removal 6 See the figure in Location of axis 1 and axis 2 motors on page 287 Only applicable to axis 1 and axis 2 motors Remove the motor cover 7 Se...

Page 293: ...CAUTION The connections for the motor brakes 24 VDC connection are phase de pendent If the connection on the pins is switched it can cause severe dam age to vital parts In order to release the brakes of the motor to be removed connect the 24 VDC power supply to the motor connector Tip For axis 2 and axis 3 motors release the mo tor brake until the arm firmly rests on the damper for each axis respe...

Page 294: ...order not to damage pinion or gears Remove the motor 16 See the figure in Location of axis 1 and axis 2 motors on page 287 Only applicable to motor axis 1 Cover the hole if replacement of motor axis 1 is not immediate in order to avoid contamina tion 17 See the figure in Location of axis 1 and axis 2 motors on page 287 Only applicable to motors axes 4 5 and 6 Check that the o ring also is removed ...

Page 295: ...ed as shown in the figure Motors 1 Axis 1 motor 2 Axis 2 motor xx0900000302 Attachment screws M5x16 quality Steel 8 A2F 7 pcs A Motor cover B Axis 1 motor Attachment screws 4 pcs washers See Tightening torques and attachment screws on page 299 C Axis 2 motor Attachment screw 4 pcs washers See Tightening torques and attachment screws on page 299 C Connection box D Axis 1 motor E Axis 2 motor E O ri...

Page 296: ...ws axis 3 motor 4 pcs washers See Tightening torques and attachment screws on page 299 B Attachment screws axis 4 axis 5 and axis 6 motors 3x4 pcs washers See Tightening torques and attachment screws on page 299 B Axis 3 motor C Axis 4 motor D Axis 5 motor E Axis 6 motor F O ring axis 4 axis 5 and axis 6 G Armhouse H Continues on next page 296 Product manual IRB 4600 3HAC033453 001 Revision Y Copy...

Page 297: ...these procedures in the step by step instructions below For art no see Reference information Lifting tool axis 2 For art no see Reference information Lifting tool axis 3 For spare part no see Spare part lists on page 391 Motors Weights The motors for the different axes weighs according to the table Weight in kg Motor 13 kg Axis 1 motor 25 kg Axis 2 motor 13 kg Axis 3 motor 8 kg Axis 4 motor 8 kg A...

Page 298: ...rbox xx1100000548 Axis 2 motor Move the robot to a position where the lower arm rests firmly on the axis 3 damper Release the axis 2 brake to be sure that the lower arm rests in the end position Axis 3 motor Move axis 2 to 0 and axis 3 to maximal Release the axis 3 brake to be sure that the upper arm is completely vertical and rests against the damper Filling oil in gearbox Use this procedure to f...

Page 299: ...ngths depending on flange thickness on page 299 Motor axis 2 22 Nm 8 8 A2F Screwlengths depending on flange thickness on page 299 Motor axis 3 22 Nm 8 8 A2F M8x25 Motor axis 4 22 Nm 8 8 A2F M8x25 Motor axis 5 22 Nm 8 8 A2F M8x25 Motor axis 6 Screwlengths depending on flange thickness Screwlengths can vary depending on when the robot is delivered The different screwlengths depends on the different ...

Page 300: ... from contamination such as oil and dirt 3 Remove any painting from the assembly sur faces with a knife Make sure that the motor and the pinion are not damaged or scratched 4 Apply Loctite 574 on the o ring 5 xx0900000082 Make sure the o ring on the flange of the motor is seated properly 6 Parts A Correct position of o ring B Incorrect position of o ring Replace with a new o ring if damaged Contin...

Page 301: ...perature is high How to install a fan is described in section Installation of cooling fan for motors option on page 82 Refitting motors Use this procedure to refit motors axes 1 2 3 4 5 and 6 Note The procedure contains information how to refit motors on all axes of the robot Some steps are only applicable to a certain motor Follow the steps carefully in order not to miss vital information Informa...

Page 302: ...5 C Wire exit hole motor axis 6 Only applicable to motors axes 4 5 and 6 7 Fit the attachment screws for the motor and fasten them sligthly The motor must be able to move parallel to the gear during the adjust ment of the play See Adjusting the play of axis 4 5 and 6 motors on page 305 Only applicable to motors axes 4 5 and 6 Adjust the play of the motor 8 Tightening torque and attachment screws a...

Page 303: ... cover is tightly sealed Applicable to motor axes 1 and 2 Refit the cable gland and motor covers Make sure that the o ring is in place 14 How to fill oil in the gearbox is de scribed in sections Changing the oil axis 2 gearbox on page 159 Changing the oil axis 3 gearbox on page 163 Applicable to motors axis 2 Refill gearbox oil 15 If the gasket is damaged it need to be replaced Applicable to motor...

Page 304: ...ity 8 8 A2F 10 pcs Tightening torque 14 Nm Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 18 Axis Calibration is described in Calib rating with Axis Calibration method on page 348 General calibration information is in cluded in section Calibration on page 335 DANGER Make sure all safety requirements are met when...

Page 305: ...llest play within this range Axis 5 motor 1 Turn the outgoing shaft for axis 4 in intervals of 90 for one full turn and find the smallest play for the axis 5 motor within this range 2 Turn the axis 5 motor one full turn at a time for a total of five turns and find the smallest play within this range Axis 6 motor 1 Turn the outgoing shaft for axis 4 in intervals of 90 for one full turn and find the...

Page 306: ...recommended to be done with the robot resting on its side Type C and Type D xx1200000637 Frame A Radial sealing B Axis 1 gearbox with O ring C Harness pipe D Washer 16 pcs E Attachment screws M10x100 quality Steel 12 9 Gleitmo 16 pcs F Continues on next page 306 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 8 1 Replacing gearbox axis 1 ...

Page 307: ...521 2 Other design than Type C and Type D Guide pin M8x150 3HAC15520 2 Guide pins Used to guide the gearbox during removal refitting Always use guide pins in pairs 3HACxxx Guide for reduction gear Used to guide axis 1 gear and frame during refit ting Content is defined in section Standard tools on page 385 Standard toolkit Continues on next page Product manual IRB 4600 307 3HAC033453 001 Revision ...

Page 308: ...n the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration i...

Page 309: ...de which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 How to drain the oil from the gearbox is described in section Changing the oil axis 1 gearbox on floor mounted robots on page 146 Drain the oil from the gearbox 2 Jog the robot to Axis 1 0 Axis 2 0 Axis 3 10 Axis 4 0 Axis 5 0 Axis 6 0 3 DANGER Turn off all electric power supply hydraulic pres...

Page 310: ...oundsling B Lifting lug C Uppermost base attachment hole D Axis 1 gearbox CAUTION The gearbox weighs 27 kg All lifting accessories used must be sized accordingly 8 Secure the gearbox in an overhead crane or similar 9 See the figure in Location of gearbox on page 306 Remove the attachment screws securing the gearbox 10 Continues on next page 310 Product manual IRB 4600 3HAC033453 001 Revision Y Cop...

Page 311: ... xx1800000790 Remove the remaining attachment screws and washers 12 Note Whenever parting mating motor and gear box the gears may be damaged if excessive force is used 13 Note There will be some excess oil running out of the gearbox when it is removed Use some absorbent material to catch the oil 14 Continues on next page Product manual IRB 4600 311 3HAC033453 001 Revision Y Copyright 2009 2021 ABB...

Page 312: ...o refit the gearbox Refitting the gearbox to the frame Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 xx1800000794 Check the radial sealing in the frame Replace if damaged 2 Continues on next page 312 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserve...

Page 313: ...t posi tion after the gearbox is fitted as shown in the figure The oil plugs shall be placed in the openings in the frame 4 A Opening for oil plug in frame B Oil plug See the figure in Location of gearbox on page 306 Replace o ring if damaged Apply grease on the o ring 5 Clean all assembly surfaces 6 Remove any painting from the assembly surfaces with a knife Continues on next page Product manual ...

Page 314: ...ction gear 3HACxxx xx1800000795 Fit the guide for the gear on top of the pro tection tube It protects the radial sealing from being damaged during refitting 8 CAUTION The gearbox weighs 27 kg All lifting accessories used must be sized accordingly 9 Continues on next page 314 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 8 1 Replacing gearb...

Page 315: ...00441 10 A Opening for oil plug in frame B Oil plug xx1800000790 Secure the gearbox with its attachment screws and washers 11 Remove the guide pins from the frame and secure the remaining two screws 12 Other design than Type C and Type D 35 Nm Type C and Type D 68 Nm xx1800000796 Remove the guide from the protection tube 13 Continues on next page Product manual IRB 4600 315 3HAC033453 001 Revision...

Page 316: ...3 See Changing the oil axis 1 gearbox on floor mounted robots on page 146 Refill oil in the gearbox 4 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 5 Axis Calibration is described in Calibrating with Axis Calibration method on page348 General calibration information is included in section Calibration on page 33...

Page 317: ...teel 12 9 Gleitmo 15 pcs A Washers 15 pcs B Gearbox axis 2 C O ring D Frame E Required equipment Note Article number Equipment See Spare part lists on page 391 Gearbox 3HAB7887 1 Rotation tool Continues on next page Product manual IRB 4600 317 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 8 2 Replacing gearbox axis 2 ...

Page 318: ...th refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 349 If no previous reference values exis...

Page 319: ...m should rest on the axis 3 damper 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 How to drain the gearbox is described in sec tion Changing the oil axis 2 gearbox on page 159 Drain the gearbox 4 Continues on next page Product manual IRB 4600 319 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All ri...

Page 320: ...rm house 7 Unload the weight of the lower and upper arm package by stretching the roundslings with the overhead crane Turn on the power temporarily and re lease the brakes of axis 2 to rest the weight onto the roundslings 8 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 9 Continues on next page 320 Product...

Page 321: ...445 Fit a lifting lug in the uppermost hole for the attachment screws that secure the lower arm to the gearbox 13 Parts A Gearbox axis 2 B Lifting lug C Holes for attachment screws that se cure the lower arm to the axis 2 gearbox Secure the gearbox with a roundsling in an overhead crane or similar 14 See the figure in Location of gearbox axis 2 on page 317 Remove the attachment screws and washers ...

Page 322: ...to damage gearbox or pinion 18 Refitting gearbox axis 2 Use this procedure to refit the gearbox Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION The gearbox weighs 51 kg All lifting accessories used must be sized accordingly 2 Continues on next page 322 Product manual IRB 4600 3HAC03345...

Page 323: ...AB3772 120 Apply some grease on the o ring before fit ting 5 See the figure in Location of gearbox axis 2 on page 317 Valid for Type C and Type D Replace if damaged Guide pin M12x150 3HAC13056 2 Fit two guide pins in opposite holes in the frame 6 Always use guide pins in pairs Secure the gearbox with a roundsling in an overhead crane or similar 7 Release the brakes of the axis 2 motor 8 Continues ...

Page 324: ...Perform a leak down test 11 Fit the guide pins to the gearbox 12 CAUTION The weight of the complete upper and lower arm together is 205 kg All lifting accessories used must be sized accordingly 13 Lift the upper and lower arms into mounting position and guide them in place with the guide pins 14 It might be necessary to rotate the motor pinion with the rotating tool to find the mat ing position At...

Page 325: ...escribed in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 18 Axis Calibration is described in Calibrating with Axis Calibration method on page348 General calibration information is included in section Calibration on page 335 DANGER Make sure all safety requirements are met when performing the first test run 19 Product manual IRB 4600 325 3HAC03345...

Page 326: ...ure Type C and Type D xx1200000638 Upper arm A Axis 3 gearbox B Washers 16 pcs C Attachment screws M10x50 quality Steel 12 9 Gleitmo 16 pcs D Continues on next page 326 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair 4 8 3 Replacing gearbox axis 3 ...

Page 327: ... page 391 Gearbox Type C and Type D M10 2 pcs Guide pins Other design than Type C and Type D M8 2 pcs Used to guide the gearbox and the upper arm during removal refitting 3HAB7887 1 Rotation tool Content is defined in section Standard tools on page 385 Standard toolkit Continues on next page Product manual IRB 4600 327 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 4 Repair ...

Page 328: ...f the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 349 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pend...

Page 329: ...ap 5 Loosen the cabling from the lower arm by unhooking the two cable brackets CAUTION The cable harness is still mounted in other parts of the robot Make sure not to damage the cable harness or any cable brackets in the continued removal 6 See Attaching the lifting accessories to the upper arm on page 252 Attach the lifting accessories to the upper arm 7 Connect the 24 VDC power supply to the axi...

Page 330: ...o rise the front end of the upper arm a little before removing the attachment screws securing the upper arm 12 CAUTION The gearbox weighs 23 kg All lifting accessories used must be sized accordingly 13 Always use guide pins in pairs Remove two attachment screws diagonally located and insert guide pins 14 See the figure in Location of gearbox axis 3 on page 326 Remove the remaining attachment screw...

Page 331: ...ouse cover 6 Attach the rotation tool on the axis 3 motor 7 Release the brakes of the axis 3 motor 8 Lift the gearbox onto the guide pins 9 Note Whenever parting mating motor and gear box the gears may be damaged if excessive force is used 10 Article number for the rotation tool is specified in Required equipment on page 327 Slide the gearbox into position while rotating the motor pinion to find t...

Page 332: ...ype C and Type D 50 Nm and 90 angle Other design than Type C and Type D 35 Nm Refit the upper arm to the lower arm with its attachment screws 18 Remove the guide pins and replace with the remaining attachment screws 19 Remove the 24 VDC power supply 20 Tightening torque 14 Nm Refit the upper armhouse cover with its at tachment screws and washers WARNING The cover on the armhouse must be fitted whe...

Page 333: ...s described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 24 Axis Calibration is described in Calibrating with Axis Calibration method on page348 General calibration information is included in section Calibration on page 335 DANGER Make sure all safety requirements are met when performing the first test run 25 Product manual IRB 4600 333 3HAC03...

Page 334: ...This page is intentionally left blank ...

Page 335: ...at is used for calibration of the robot Calibration position A generic term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine ca...

Page 336: ...chanical 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 option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is deliver...

Page 337: ...ing manual Calibration Pendulum which describes the method and the different routines further Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 4600 and is the most accurate method for the standard calibration It is the recommended method in order to achieve proper performance The following routines are available for the Axis Calibration method Fine c...

Page 338: ...curacy 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 386 The calibration equipment for Calibration Pendulum is delivered as a complete t...

Page 339: ...age 344 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 ...

Page 340: ...ronization position for each axis Synchronization marks IRB 4600 IRB 4600 60 2 05 45 2 05 40 2 55 20 2 50 xx0800000312 Synchronization mark axis 1 A Synchronization mark axis 2 B Synchronization mark axis 3 C Continues on next page 340 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position...

Page 341: ... The two tips of the arrows should be inside the corresponding groove on the tilt housing when in synchronization position F Continues on next page Product manual IRB 4600 341 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 342: ...ization mark axis 5 E IRB 4600 20 2 50 xx0800000321 Synchronization mark axis 6 F 342 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 343: ...nes will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which is in the opposite direction xx0200000089 Product manual IRB 4600 343 3HAC033453 001 Rev...

Page 344: ...motion mode 1 See Synchronization marks and synchron ization position for axes on page 340 Jog the manipulator to align the synchron ization marks 2 Step 2 Updating the revolution counter with the FlexPendant on page 345 When all axes are positioned update the revolution counter 3 Correct calibration position of axis 4 and 6 When jogging the manipulator to synchronization position it is extremely ...

Page 345: ... 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 FlexPendant Use this procedure to update the revolution counter with the FlexPendant IRC5 Action On the ABB menu tap Calibration xx1500000942 1 Continues on next page Prod...

Page 346: ...RobotWare 6 02 and later 3 Calibration method used at factory for each axis is shown as well as calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 Continues on next page 346 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 347: ...s displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn ma...

Page 348: ...able calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the FlexPendant WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB Using other pins in the calibration bushings may cause severe damage to the robot and or personnel WARNING The calibration tool must be fully inser...

Page 349: ...l data about the tool installed A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory The reference value will be named according to tool name date etc Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values When reference calibration is performed the robot...

Page 350: ...s 5 Axis 4 Axis 3 Axis 2 Axis 1 Required position of axis Axis 1 0 0 Axis 2 0 0 Axis 3 0 0 Axis 4 0 Axis 5 Axis 6 Axis to be calibrated Unrestricted Axis is allowed to be jogged to other position than 0 degrees Axis must be put in position 0 degrees 0 How to calibrate a suspended robot The IRB 4600 is fine calibrated floor standing in factory prior to shipping To calibrate a suspended robot refere...

Page 351: ...nd or personnel Note Article number Equipment etc Delivered as a set of calibration tools Required if Axis Calibration is the valid calib ration method for the robot Contains a removal tool for removing special protection plugs on the turning disk 3HAC074119 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure tha...

Page 352: ... should be checked Outer diameter within Ø12g4 mm Ø8g4 mm or Ø6g5 mm depending on calibration tool size Straightness within 0 005 mm xx1500000951 Outer diameter A 352 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 5 Calibration 5 4 2 Calibration tools for Axis Calibration Continued ...

Page 353: ...n and a bushing for the movable calibration tool are located on each axis as follows If there is not enough space on an axis to install a fixed calibration pin the axis is equipped with two bushings instead for installation of two calibration tools when calibration is carried out This is shown in the figure xx1600000641 Continues on next page Product manual IRB 4600 353 3HAC033453 001 Revision Y C...

Page 354: ...0 20 2 50 xx1600000643 Continues on next page 354 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools Continued ...

Page 355: ... number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC059487 001 protection type Standard Protection cover and plug set Only on IRB 4600 20 2 50 3HAC057511 001 Protective plug on turning disc Replace if damaged or missing Product manual IRB 4600 355 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 5 Calibration 5 4 3 Installati...

Page 356: ...rotection type Standard Protection cover and plug set Only on IRB 4600 20 2 50 3HAC057511 001 Protective plug on turning disc Replace if damaged or missing 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 st...

Page 357: ...ing ring snaps into place 9 The robot moves to verify that the calibration tool is removed 10 Choose whether to save the calibration data or not Calibration of the robot is not finished until the calibration data is saved as last step of the calibration procedure Preparation prior to calibration The calibration procedure is described in the FlexPendant while conducting it Note Action DANGER While ...

Page 358: ...timiza tion method on page 365 Starting the calibration procedure Use this procedure to start the Axis Calibration routine on the FlexPendant Note Action On the ABB menu tap Calibration xx1500000942 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question xx1500000943 Continues on next page 358 Product manual IRB 4600 3HAC033453 0...

Page 359: ...ice and press Play The three position enabling device on the FlexPendant has been released during robot movement Remove the calibration tool if it is installed and restart the calibration procedure from the beginning See Starting the calibration procedure on page 358 The RobotWare program is terminated with PP to Main If the calibration tool is in contact the robot axis needs to be jogged in order...

Page 360: ...new spare part if missing or damaged 2 Protection cover and plug set 3HAC059487 001 protection type Standard xx1500000952 Reinstall the protective plug and sealing in the bushing on each axis directly after the axis has been calibrated Ensure that the sealing is not damaged Replace the plug and the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC059487 001 pro...

Page 361: ... on page 365 If the standard calibration data for axes 4 5 or 6 should be updated with wrist optimization run the calibration routine Wrist Optimization 6 Product manual IRB 4600 361 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 5 Calibration 5 4 4 Axis Calibration Running the calibration procedure Continued ...

Page 362: ...to save reference values for all axes that is to be replaced Make sure that the values are saved in RobotStudio or FTP program The files are located in Active system folder name HOME RefCalibFiles 7 Perform the repair 8 Make sure that the tooling and process equipment are the same as when creating the reference Use Reference calibration to update the system with new calibration offset value for th...

Page 363: ...ie 96 3 94 2 2 1 degrees 8 Manually jog axis 4 the calculated angle difference 2 1 NOTE The direction shall be the same direction as the direction used when axis 4 was manually jogged to coincide with the verification process In the example 2 1 degrees 9 Make a new manual fine calibration of axis 4 with axis in 2 1 degrees position 10 Check again against the verification position 11 Repeat the man...

Page 364: ...ndulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools 364 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 5 Calibration 5 5 Calibrating with Calibration Pendulum method ...

Page 365: ...e will be run 1 Choose calibration routine Wrist Optimization 2 Modify targets for 4 point tool frame definition in Wrist Optimization routine en0400000906 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...

Page 366: ...ion program twice Do not change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 340 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the lower arm 366 Produc...

Page 367: ...page 340 and Updating revolution counters on page 344 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis ...

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Page 369: ... 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 robo...

Page 370: ...atteries Lithium Base lower arm upper arm Cast iron nodular iron Cables motors Copper Brakes motors Neodymium Turning disc foundry Nickel Gearboxes Oil grease Cables connectors drive belts and so on Plastic rubber Gears screws base frame and so on Steel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local re...

Page 371: ...o organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination Product manual IRB 4600 371 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 6 Decommissioning 6 2 Environmental information Continued ...

Page 372: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed 372 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All r...

Page 373: ...Axis 1 and 3 new gearboxes Axis 3 new gearbox Axis 3 new gearbox IRB 4600 60 2 05 IRB 4600 45 2 05 IRB 4600 40 2 55 Standard Foundry Plus 2 Axis 4 5 and 6 new motors Axis 1 and 3 new gearboxes Axis 3 new gearbox Axis 3 new gearbox IRB 4600 20 2 50 Standard Foundry Plus 2 Product manual IRB 4600 373 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 7 Robot description 7 1 Manipu...

Page 374: ...boxes Notable changes connected to the Type C gearboxes Dimension and number of attachments screws are different Washers between the lower arm and axis 3 gearbox are different Tightening torques are different Tightening torque with angle 90 degrees added when the lower arm is secured to the axis 3 gearbox The frame and base are redesigned to fit the axis 1 gearbox and are not compatible with other...

Page 375: ...IRB 4600 uses a Type C of IRB 4600 on page 374 with an alternative motor and is only valid for the 20 kg 2 50 m variant Product manual IRB 4600 375 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 7 Robot description 7 3 Type D of IRB 4600 ...

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Page 377: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 4600 377 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 8 Reference information 8 1 Introduction ...

Page 378: ...r design ISO 13849 1 2006 Safety of machinery Emergency stop Principles for design ISO 13850 Safety of machinery Electrical equipment of machines Part 1 General requirements IEC 60204 1 2005 Safety of machinery Functional safety of safety related elec trical electronic and programmable electronic control systems IEC 62061 2005 Region specific standards and regulations Description Standard Safety r...

Page 379: ...014i Classification of air cleanliness ISO 14644 1 2015ii Degrees of protection provided by enclosures IP code IEC 60529 1989 A2 2013 i Only valid for arc welding robots Replaces IEC 61000 6 4 for arc welding robots ii Only robots with protection Clean Room Product manual IRB 4600 379 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 8 Reference information 8 2 Applicable stand...

Page 380: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 380 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 8 Reference information 8 3 Unit conversion ...

Page 381: ...d be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions o...

Page 382: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 383: ...ning torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 4600 383 3HAC033453 001 Rev...

Page 384: ...essory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The arm weighs 25 kg All lifting accessories used must be sized accord ingly 384 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB A...

Page 385: ...rd toolkit and any tools listed in the instruction Contents standard toolkit Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Torque wrench 10 100 Nm 1 Small screwdriver 1 Plastic mallet 1 Ratchet head for torque wrench 1 2 1 Socket head cap no 5 socket 1 2 bit L 20 mm 1 Socket head cap no 6 socket 1 2 bit L 20 mm 1 Socket head cap no 8 socket 1 2 bit L 2...

Page 386: ...he product manual Art no Qty Description 2 pcs Guide pins removal refitting of axis 1 gearbox 2 pcs Guide pins removal refitting of axis 3 gearbox Oil change equipment The following table specifies the oil change equipment The tool is specified directly in concerned instructions in the product manual Art no Included parts Description 3HAC021745 001 vacuum pump with regulator hose and coupling coup...

Page 387: ...g the robot with the Axis Calibration method The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory Always use the same calibration method as used at the factory Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant If no data is found related to standard calibration Calibration Pendulum is used as ...

Page 388: ...ting accessory axis 2 Lifting accessory axis 3 For lifting of upper arm 2 pcs Rotating lifting point Dimension M8 Example Gunnebo RLP GrabiQ M8 10 xx1100000564 Special tools This table specifies the special tools required during several of the service procedures The tools are specified directly in concerned instructions Article no Qty Description 3HACxxx 1 Guide for reduction gear Used to guide ax...

Page 389: ...ting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 4600 389 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 8 Reference information 8 8 Lifting accessories and lifting ...

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Page 391: ...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 Product manual IRB 4600 391 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 9 Spare part lists 9 1 Spare part lists and illustrations ...

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Page 393: ...C025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB 2400 3HAC029570 ...

Page 394: ...Circuit diagram IRB 6700 IRB 6790 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram IRB 14000 3HAC056159 002 Circuit diagram IRB 910SC 394 Product manual IRB 4600 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved 10 Circuit diagram 10 1 Circuit diagrams Continued ...

Page 395: ...ioxide extinguisher 33 cast iron disposal 370 cleaning 184 climbing on robot 36 Cold environments 95 connecting the robot and controller cabling 96 copper disposal 370 D direction of axes 343 E environmental information 370 ESD damage elimination 53 sensitive equipment 53 expansion container installing 90 expected life 109 F fire extinguishing 33 FlexPendant jogging to calibration position 367 Mov...

Page 396: ...ymbols 25 rubber disposal 370 S safety brake testing 40 ESD 53 fire extinguishing 33 release robot axes 39 signals 23 signals in manual 23 symbols 23 symbols on robot 25 safety devices 33 safety hazard hydraulic system 34 pneumatic system 34 safety signals in manual 23 safety standards 378 scales on robot 340 schedule for maintenance 107 screw joints 381 signals safety 23 special tools 386 speed a...

Page 397: ...42 243 robot 55 63 239 259 261 266 269 280 282 310 314 321 322 330 331 upper and lower arm 320 324 upper arm complete 250 255 Wrist Optimization overview of method 365 Z zero position checking 367 Product manual IRB 4600 397 3HAC033453 001 Revision Y Copyright 2009 2021 ABB All rights reserved Index ...

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Page 400: ... 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics Discrete Automation No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics Discrete Automation 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC033453 001 Rev Y en Copyright 2009 2021 ABB All rights reserved Specifications subject to change without notice ...

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