Page 1 ABB Robotics Product manual IRB 4600...
Page 2 Trace back information: Workspace R13-2 version a3 Checked in 2013-10-15 Skribenta version 4.0.378...
Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Setting the system parameters for a suspended robot ........2.3.6 Fitting equipment on robot ................ 2.3.7 Loads ....................2.3.8 Installation of signal lamp (option) .............. Restricting the working range ................2.4.1 Introduction .................... 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 6 Refitting the complete cable harness ............4.3.3 Replacing SMB unit ................. 4.3.4 Replacing the brake release unit ..............4.3.5 Replacing the base .................. Upper arm ....................... 4.4.1 Replacing the complete upper arm ............. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 7 Upper arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55 ..........Wrist unit (60 kg/45 kg/20 kg) ................Electrical connections ..................Gearboxes ....................... Motors ......................9.10 Labels ......................9.11 Options ......................10 Circuit diagram 10.1 About circuit diagrams ..................3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 9: Overview Of This Manual
Prerequisites A maintenance/repair/installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter...
Page 10 Application manual - Additional axes and stand alone controller 3HAC021395-001 Application manual - Electronic Position Switches 3HAC027709-001 Application manual - CalibWare Field 5.0 3HAC030421-001 Revisions Revision Description First edition Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 11 Safety signals in the manual on page • New safety labels on the manipulators, see Safety symbols on manipu- lator labels on page • Revised teminology: robot replaced with manipulator. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 12 Standard IRB 4600. The in- structions for a IRB 4600 Foundry prime can be found in a separate manual. For art. No. See References on page Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 13 Replacing the base on page 232. • Changed type of oil in axes 1, 3 and 4 gearboxes. See Type of lubrication in gearboxes on page 148. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 14 The spare part number is added. • A new SMB unit and battery is introduced, with longer battery lifetime. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 15 Several more spare part numbers are corrected throughout the spare part chapter. • Section describing inspection of oil level in axis-1 gearbox for suspended robots is clarified, see Inspecting oil level, axis 1 gearbox on page 114. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 16: Product Documentation, Irc5
All documents listed can be ordered from ABB on a DVD. The documents listed are valid for IRC5 manipulator systems. Product manuals...
Page 17 Operating manual - Introduction to RAPID • Operating manual - IRC5 with FlexPendant • Operating manual - RobotStudio • Operating manual - Trouble shooting IRC5, for the controller and manipulator. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 18: How To Read The Product Manual
Likewise certain work methods or general information, that is valid for several robot models, can be illustrated with pictures that show a different robot model that the one described in the current manual. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 19: Safety
Specific safety information, pointed out in the procedures. How to avoid and eliminate the danger is either described directly in the procedure, or in specific instructions in the section Safety related instructions on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 20: General Safety Information
• stopping functions Safety stops describes different types of • description of emergency stop stops. • description of safety stop • description of safeguarding 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 21: Safety In The Manipulator System
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial manipulator will not cause injury or damage even if all safety instructions are complied with. Related information...
Page 22: Safety Risks
ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the manipulator system.
Page 23 Removed cables to the measurement sys- WARNING If the internal cables for the measurement system have been disconnected during repair or maintenance, then the revolution counters must be updated. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 24 Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balan- cing device is potentially lethal! 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 25: Caution - Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 26: Safety Risks Related To Tools/Work Pieces
Unauthorized modifications of the originally delivered manipulator are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected.
Page 27: Safety Risks Related To Pneumatic/Hydraulic Systems
Gravity may cause any parts or objects held by these systems 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. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 28: Safety Risks With Pressure Relief Valve
The pressure relief valve is a vital part preventing too much air pressure being built up inside the manipulator. If too much air pressure has been built up, there is a risk of personal injury and mechanical damage. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 29: Safety Risks During Operational Disturbances
If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 30: Risks Associated With Live Electric Parts
The power supply unit for additional tools, or special power supply units for the machining process. • The external voltage connected to the controller remains live even when the robot is disconnected from the mains. • Additional connections. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 31 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 32: Safety Actions
(see the section Robot motion in the Product specification). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 33: Fire Extinguishing
1 Safety 1.2.4.2 Fire extinguishing 1.2.4.2 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 34: Emergency Release Of The Manipulator's Arm
Increased injury Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury! 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 35: Brake Testing
3 Check 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. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 36: Risk Of Disabling Function "Reduced Speed 250 Mm/S
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" Note Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 37: Safe Use Of The Flexpendant
The hold-to-run function can only be used in manual mode. How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 38: Work Inside The Manipulator's Working Range
NEVER, under any circumstances, stay beneath any of the manipulator’s axes! There is always a risk that the manipulator will move unexpectedly when manipulator axes are moved using the enabling device or during other work inside the manipulator’s working range. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 39: Signal Lamp (Optional)
Function The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 40: Safety Stops
Emergency stop should not be used for normal program stops as this causes extra, unnecessary wear on the manipulator. For how to perform normal program stops, see section Stopping programs in Operating manual - IRC5 with FlexPendant. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 41 Dual Cabinet Controller). There can also be other types of emergency stops on your manipulator. Consult your plant or cell documentation to see how your manipulator system is configured. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 42: Safety Related Instructions
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 43 1.3.1 Safety signals in the manual Continued Symbol Designation Significance NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 44: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 45 Pressing this button will release the brakes. This means that the manipulator arm can fall down. xx0900000808 Tip risk when loosening bolts The manipulator can tip over if the bolts are not securely fastened. xx0900000810 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 46 Risk of crush injuries. xx0900000817 Heat Risk of heat that can cause burns. xx0900000818 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 Brake release buttons xx0900000820 xx1000001140 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 47 Mechanical stop xx0900000824 No mechanical stop xx1000001144 Stored energy Warns that this part contains stored energy. Used in combination with Do not dismantle symbol. xx0900000825 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 48 Symbol Description Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level. xx0900000826 Shut off with handle Use the power switch on the controller. xx0900000827 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 49: Danger - Moving Manipulators Are Potentially Lethal
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the manipulator be- fore pressing the start button. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 50: Danger - First Test Run May Cause Injury Or Damage
CAUTION When programming the movements of the manipulator always check potential collision risks before the first test run. Mechanical stops will not always stop the movements of the manipulator completely. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 51: Warning - The Brake Release Buttons May Be Jammed After Service Work
Make sure none of the buttons are jammed in the tube. If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes! 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 52: Danger - Make Sure That The Main Power Has Been Switched Off
Note/illustration Switch off the main switch on the Drive Module. xx0600002783 K: Main switch, Drive Module Switch off the main switch on the Control A: Main switch, Control Module Module. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 53: Warning - The Unit Is Sensitive To Esd
Location of wrist strap button The location of the wrist strap button is shown in the following illustration. IRC5 The wrist strap button is located in the top right corner. xx1300000856 Wrist strap button 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 54: Warning - Safety Risks During Handling Of Batteries
Risk of fire or explosion. page Use safety glasses when handling the batteries. In the event of leakage, wear gloves and chemical apron. In the event of fire, use self-contained breathing apparatus. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 55: Warning - Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Do not present in the gearbox, causing overfill the gearbox when filling. lubricant to spray from the xx0100000002 opening. Possible pressure build-up in gearbox Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 57: Installation And Commissioning
If the IRB 4600 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work! For more information see: • Product manual - IRC5 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 58: Unpacking
It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation Installation craftsmen working with an ABB robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 59 ±1610 Nm ±2960 Nm Suspended Force Endurance load (in operation) Max. load (emergency stop) Force xy ±3940N ±7790 N Force z -4350 ±2460N -4350 ±6360 N Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 60 Maximum tilt 15° The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°. Contact ABB for further information about accept- able loads. Minimum resonance 22 Hz frequency Storage conditions, robot...
Page 61: Working Range And Type Of Motion
1735 mm 1393 mm 680 mm 2202 mm 2552 mm IRB 4600 - 20/2.50 2833 mm 1696 mm 1361 mm 665 mm 2163 mm 2513 mm Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 62 1735 mm 1393 mm 680 mm 2202 mm 2552 mm IRB 4600 - 20/2.50 2833 mm 1696 mm 1361 mm 665 mm 2163 mm 2513 mm Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 63 +150° / -90° Axis 3 Arm motion +75° / -180° Axis 4 Wrist motion ±400° Axis 5 Bend motion +120° / -125° Axis 6 Turn motion ±400° Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 64 ±180° Axis 2 Arm motion +150° / -90° Axis 3 Arm motion +75° / -180° Axis 4 Wrist motion ±400° Axis 5 Bend motion ±120° Axis 6 Turn motion ±400° 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 65: Risk Of Tipping/Stability
The position of the calibration mark (A) in the figure is approximate and is used as aming aid. 0° xx0800000263 WARNING The robot is likely to be mechanically unstable if not secured to the foundation! 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 66: On-Site Installation
Attach the roundslings as shown in the figure. xx0800000262 Roundsling put folded in U-shape through the lifting lug Roundsling put folded in U-shape around gearbox axis 3 Lifting lug Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 67 U-shape around the gear- • Lifting on page 66 box. Make sure the roundslings do not rub against any sharp edges. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 68 • A: Area where the connection box can be damaged while lifting. Lift the robot with an overhead crane. Lifting capacity: • Required equipment on page 66 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 69: Lifting And Turning A Suspended Mounted Robot
Special tools on page 342. Contact ABB for more information. How to lift and turn the robot into position for wall or tilted position: Contact ABB for more information! Illustration xx1000000181...
Page 70: Manually Releasing The Brakes
The brake will function again as soon as the button is released. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 71 The buttons are numbered accord- pressed. ing to the numbers of the axes. See the previous figure. The brake will function again as soon as the button is released. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 72 DANGER When power is connected directly to the brake cable, the brake will be released imme- diately when the power is switched on. This may cause some unexpected robot movements! 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 73: Orienting And Securing The Robot
The illustration shows the hole configuration used when securing the robot. xx0800000271 Center axis 1. See graphic in Fitting equipment on base and frame on page Hole for guide sleeve Rear bolt holes Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 74 6 pcs Guide sleeves (2 pcs) Article number: 21510024-169 Added to the rear bolt holes, to allow the same robot to be re-mounted without program adjustments. xx1200000885 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 75 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 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 76: Setting The System Parameters For A Suspended Robot
How to calculate a new value is detailed in Mounting angles and values on page The parameter is described in Technical reference manual - System parameters. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 77 The parameter can be edited either with the FlexPendant or in RobotStudio. See Operating manual - IRC5 with FlexPendant or Operating manual - RobotStudio. Article numbers for the manuals are specified in References on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 78: Fitting Equipment On Robot
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.
Page 79 The illustrations show the fitting holes available for fitting extra equipment on the base and frame of the robot. xx0800000276 Attachment holes on base Center axis 2 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 80 The illustrations show the fitting holes available for fitting extra equipment on the lower and upper arm of the robot. 216 (2x M8 16) (3x M8 3x M8 2x M8 16 xx0800000280 Center axis 4 Center axis 3 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 81 1095 1586 1270 20/2.50 1922 1095 1496.5 1230.5 Position H and measurement C is only applicable to IRB 4600 - 40/2.55 and IRB 4600 - 20/2.50. Variant Attachment screws 60/2.05 4x M8, through 45/2.05 4x M8, through 40/2.55 6x M8, through 20/2.50...
Page 82 Screw hole intended for swivel fitting. Extra equipment on mounting flange, robot versions IRB 4600 -60/2.05, -45/2.05 and -40/2.55 The illustration shows the mechanical interface for the mounting flange. xx0800000282 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 83 6 H7 8 0,05 2x M 6 12 6x M6 A = R98 xx0800000278 Smallest circumscribed radius axis 4 Note Use attachment screws M6, quality 12.9 and 10 mm used thread length. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 84: Loads
Operating manual - IRC5 with FlexPendant Stop time and braking distances Robot motor brake performance depends on any loads attached. For information about brake performance, read the product specification for the robot. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 85: Installation Of Signal Lamp (Option)
2 Installation and commissioning 2.3.8 Installation of signal lamp (option) 2.3.8 Installation of signal lamp (option) Signal lamp See the assembly instruction delivered with the signal lamp. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 86: Restricting The Working Range
This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 87: Mechanically Restricting The Working Range Of Axis 1
Other tools and procedures These procedures include references to the may be required. See refer- tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 88 Fit the stop lugs firmly with attachment Specified in Required equipment on screws and washers according to the figure page Additional stops on page Tightening torque: 82 Nm Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 89 Remove the two screws holding the mechan- ical stop and the bracket. xx1100000091 A Attachment screw B Bracket, stop axis 1 Remove the bracket. Refit the attachment screws. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 90: Installing Options
The fans are installed on the motors, axes 1-2, as shown in the figure below. xx0900000135 Fan, motor axis 2 Fan, motor axis 1 Protection cover Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 91 The details of the cooling fan are shown in the figure below. xx0500002158 Fanbox (motor axis 2) Attachment screws, fanbox plates (9 pcs) Groove in the connector Tightening screws, fanbox (3 pcs) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 92 Other tools and procedures These procedures include references to may be required. See refer- the tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 93 A: Connection box • B: Position where the fan shall be aligned with connection box • C: Fan Fit the fanbox with two attachment screws M6x25. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 94 Parts: • A: Protection cover • B: Fan Secure the fan cable to the protection cover with a cable strap. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 95 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 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 96 Continued Action Note After fitting the motor cover, fit the protection cover using two attachment screws for the mo- tor cover. xx0900000406 Parts: • A: Protection cover • B: Fan 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 97: Installation Of Foundry Plus Cable Guard (Option No. 908-1)
Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are 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 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 98: Installing An Expansion Container
Attachment screw M6x16, quality 8.8-A2F (5 pcs) Oil expansion container with cover Base O-ring D220x5 Attachment screw M5x20, quality 8.8-A2F and washer (2+2 pcs) O-ring D1=9.5 D2=1.6 Oil plug (to be removed) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 99 150. Turn the robot to suspended position. Inspect the oil level. See procedure for suspended robot, specting oil level, axis 1 gearbox on page 114. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 100: Robot In Hot Environments
Let the overpressure leave the gearbox. Refit the oil plug. Continue releasing the overpressure on all gearboxes. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 101: Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 102: Electrical Connections
Art. no. Robot cable, power: 7 m 3HAC026787-001 Robot cable, power: 15 m 3HAC026787-002 Robot cable, power: 22 m 3HAC026787-003 Robot cable, power: 30 m 3HAC026787-004 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 103 The cables are 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 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 104: Customer Connection On Robot
The customer connections are located on the robot as shown in the figure. Customer connection upper arm. xx0800000289 Air M16x1.5 (24° cone sealing) R2.CP R2.CS Customer connections base xx0800000288 R1.CP/CS Air M16x1.5 R1.CBUS R1.SMB Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 105 R1.CP/CS 3HAC033181-001 • M12 connector, male on base • Pins for cable area 0.21 - 0.93 R2.CP/R2.CS R2.CP/R2.CS 3HAC025396-001 mm² • Bottle shaped shrinking hose • Angle shaped shrinking hose 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 106: Customer Connections On Upper Arm
R1.CP/CS.d1 XP6.2 R2.CP.B R1.CP/CS.d6 XP6.3 R2.CP.C R1.CP/CS.d3 XP6.4 R2.CP.D R1.CP/CS.d4 XP6.1 R2.CP.E R1.CP/CS.d1 XP6.2 R2.CP.F R1.CP/CS.d6 R2.CP.G (Earth) R2.CP.H R1.CP/CS.d7 XP6.3 R2.CP.J R1.CP/CS.d3 XP6.4 R2.CP.K R1.CP/CS.d4 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 107 XP5.1.6 R2.CS.P R1.CP/CS.b14 XP5.3.1 R2.CS.R R1.CP/CS.b15 XP5.3.2 R2.CS.S R1.CP/CS.b16 XP5.3.3 R2.CS.T R1.CP/CS.b18 XP5.3.4 R2.CS.U R1.CP/CS.b19 XP5.3.5 R2.CS.V R1.CP/CS.b20 XP5.3.6 R2.CS.W R1.CP/CS.b21 XP5.2.9 R2.CS.X R1.CP/CS.b22 XP5.2.10 R2.CS.Y R1.CP/CS.b23 XP5.2.11 R2.CS.Z R1.CP/CS.b24 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 108 This page is intentionally left blank...
Page 109: Maintenance
If the IRB 4600 is connected to power, always make sure that the IRB 4600 is connected to protective earth before starting any maintenance work! For more information see: • Product manual - IRC5 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 110: Maintenance Schedule
The SIS used in M2004 is further described in the Operating manual - Service Information System. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 111: Maintenance Schedule
Oil in axis-2 gearbox First change when DTC reads: • 6,000 hours Second change when DTC reads: • 24,000 hours Following changes: • Every 24,000 hours. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 112 Additional mechanical Every: stop, axis 1 12 months Inspection Motor fan Every 12 Inspect the fan for contam- months ination that could hinder the air supply. Clean if ne- cessary. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 113: Expected Component Life
SIS (See the Operating manual - Service Infomation System) In applications such as Foundry or Washing the robot can be exposed to chemicals, high temperature or humidity which can have an effect on the lifetime of gearboxes. Contact the local ABB Robotics Service team for more information.
Page 114: Inspection Activities
341. Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 115 Type C xx1200000632 Oil plug, filling and inspection Oil plug, draining Other design (1) than Type C xx0800000304 Oil plug, inspection Oil plug, gearbox Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 117 How to fill oil is described in section: • Changing the oil, axis-1 gearbox on floor mounted robots on page 150 Refit the oil plug, inspection. Tightening torque: • 24 Nm Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 118 Oil plug, draining Other design (2) than Type C xx1000001436 Filling oil plug, on gearbox Draining oil plug, on surface for motor flange Surface for motor flange Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 119 Open the oil plug inspection on the axis 1 See the figure in: gearbox. • Location of oil plugs (floor moun- ted) on page 115 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 120 Only valid for Other design than Type C: 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. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 121: Inspecting The Oil Level, Axis 2 Gearbox
341. Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 122 Only valid for Other design than Type C: 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. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 123: Inspecting The Oil Level, Axis 3 Gearbox
The oil plug for inspection is shown in the figure. Type C xx1200000633 Oil plug, armhouse (Not visible in this figure. See enlarged figure!) Oil plug, armhouse Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 124 - Safety risks during work with gearbox lub- ricants (oil or grease) on page Move the robot to where the upper arm is placed in a +30° position. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 125 Refit the oil plug. Tightening torque: • Other design than Type C, in armhouse: 10 Nm Other design than Type C, in gearbox: 3 Nm Type C, both plugs: 10 Nm 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 126: Inspecting The Oil Level, Axis 4 Gearbox
Before proceeding, please read the safety information in the section WARNING - Safety risks during work with gearbox lub- ricants (oil or grease) on page Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 127 Add oil if required. How to fill oil is described in section: • Changing the oil, axis-4 gearbox on page 172 Refit the oil plug, filling. Tightening torque: • 10 Nm 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 128: Inspecting Oil Level, Gearbox Axes 5 - 6
The figure shows IRB 4600 -20/2.50 with wrist 12/20 kg xx0900000139 Oil plug, tilthouse Oil plug, wrist (also used as air inlet when draining from oil plug A) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 129 This will level up oil in axes 5 and 6. See the figure in: • Inspecting oil level, gearbox axes 5 - 6 on page 128 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 130 See the figure in: • Location of gearbox, axes 5-6 on page 128 Required oil level: • 63 ±3 mm below the edge of the oil plug hole. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 131 If necessary, refill oil. How to fill oil is described in section: • Changing oil, axes-5 and -6 gear- boxes on page 176 Refit the oil plug. Tightening torque: • 10 Nm 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 132: Inspecting The Cable Harness
These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram See chapter Circuit diagram on page 369. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 133 Check all brackets and straps are properly attached to the robot. Replace the cable harness if wear, cracks or How to replace the cable harness is de- damage is detected. scribed in Repair on page 189. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 134: Inspecting Information Labels
Label - Lifting instruction Warning - High temperature Label - Max. air pressure Warning - Brake release unit Label - Calibration AbsAcc Information Sign UL-Label Oil quality Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 135 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 136 3 Maintenance 3.3.7 Inspecting information labels Continued Action Note Check all labels. See the figure in Location of information labels on page 134. Replace any missing or damaged labels. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 137: Inspecting The Mechanical Stop Pin, Axis 1
Other tools and procedures These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired. the step-by-step instructions below. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 138 Check that the mechanical stop pin is prop- erly attached. xx0800000045 Parts: A Attachment screws B Bracket C O-ring (2 pcs) D Bracket E Stop pin Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 139 3.3.8 Inspecting the mechanical stop pin, axis 1 Continued Action Note Check that the mechanical stop pin can move freely in both directions and the bracket works as it is supposed to. xx1000000222 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 140: Inspecting Additional Mechanical Stops
Other tools and procedures may be re- These procedures include references to the quired. See references to these procedures tools required. in the step-by-step instructions below. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 141 • 82 Nm If any damage on stops or attachment screws Attachment screws: etc. is detected, the mechanical stops must • M12x40, quality 8.8-A3F be replaced! • 2 pcs/stop lug 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 142: Inspecting Dampers
DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 143 Location of dampers on page 142 Check all dampers for existing impressions larger than 2-3 mm. Check attachment screws for deformation. If any damage is detected the damper must be replaced. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 144: Inspecting The Pressure Relief Valve
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. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 145 Check if the pressure relief valve is not con- See the figure in: taminated or covered with litter. • Location of the pressure relief valve on page 144 Clean if necessary. Note Use a cloth or a brush! 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 146: Inspecting Signal Lamp (Option)
If the signal lamp is damaged, it shall be replaced! Action Note Check that the signal lamp is lit when motors are put in operation ("MOTORS ON"). Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 147 Check whether the signal lamp is broken. If so, replace. Check the cable connections. Measure the voltage in connectors, motor axis 3. Check the cabling. If a fault is detected, re- place. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 148: Replacement Activities
In order to always get the latest information of updates about lubrication in gearboxes, always check on ABB Library for the latest revision of the manual. A new revision will be published on ABB Library immediatly after any updates.
Page 149 Other design than Type C: Used on the axis-2 gearbox. Not valid for type C: Used when the robot is fitted in a suspended position. Expansion container, gearbox axis 1 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 150: Changing The Oil, Axis-1 Gearbox On Floor Mounted Robots
Oil plugs for filling and draining are not depending on in which position the robot is mounted: • Draining = Oil plug on base. • Filling = Oil plug on surface for motor flange. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 151 • 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 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 152 3.4.2 Changing the oil, axis-1 gearbox on floor mounted robots Continued xx0800000304 Oil plug, filling Oil plug, draining xx1000000669 Oil plug, draining Oil plug, filling Surface for motor flange Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 153 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. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 154 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. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 155 Only valid for Other design than Type C: 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. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 156: Changing The Oil, Axis-1 Gearbox On Suspended Robots
Filling = Oil plug on surface for motor flange. Mounted in suspended position: • Filling = Oil plug on surface for motor flange. • Draining = Oil plug on surface for motor flange. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 157 Oil dispenser One example of oil dispenser can be found in section: • Type of lubrication in gearboxes on page 148 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 159 Handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section WARNING - Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 160 Expansion container axis-1 gearbox, suspended mounted robots Note Not valid for Type C! Expansion container is not needed on Type C. This applies both to suspended and wall mounted robots. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 161 The expansion container is installed on delivery 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 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 162: Changing The Oil, Axis-2 Gearbox
Location of oil plugs on page 162. Standard toolkit Content is defined in section Standard tools on page 341. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 163 WARNING Used oil is hazardous material and must be disposed of in a safe way. See section commissioning on page 329 for more inform- ation. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 164 Type and amount of oil in gearboxes on page 148. Note The amount of oil to be filled depends on the amount previously being drained. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 165 Only valid for Other design than Type C: 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. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 166: Changing The Oil, Axis-3 Gearbox
The axis-3 gearbox is located in the upper arm rotational center. Oil plugs are shown in the figure. Type C xx1200000633 Oil plug, armhouse (not visible in this figure) Oil plug, armhouse Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 167 One example of oil dispenser can be found in section: • Type of lubrication in gearboxes on page 148 Funnel xx1200000862 Standard toolkit Content is defined in section Standard tools on page 341. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 168 • Location of oil plugs on page 166 Other design than Type C: Open the oil plug, gearbox and use it as a ventilation hole. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 169 Location of oil plugs on page 166 Connect the oil dispenser. One example can be found in section: • Type of lubrication in gear- boxes on page 148 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 170 Use this procedure to fill the gearbox with oil. Action Note Move the upper arm to a position where the wrist is pointing towards the floor as shown in the figure. xx0800000329 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 171 Refit the oil plug. Tightening torque: Other design than Type C, in arm- house: 10 Nm Other design than Type C, in gear- box: 3 Nm Type C, both plugs: 10 Nm 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 172: Changing The Oil, Axis-4 Gearbox
Used for venting the gearbox during draining. A suitable hose would be a hose normally used for compressed air. Length: minimum 300 mm. Diameter: 5 mm. Funnel xx1200000862 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 174 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 175 148. Use a funnel. Note The amount of oil to be filled depends on the amount previously being drained. Refit the oil plug. Tightening torque: 10 Nm. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 176: Changing Oil, Axes-5 And -6 Gearboxes
The figure shows wrist variant 60 kg xx0800000308 Oil plug, tilthouse Oil plug, wrist unit (also used as air inlet when draining from oil plug A) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 177 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. Action Note Move the upper arm to a position where it points downwards. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 178 Action Note Move the upper arm to a horizontal position. Turn axis-4 to the calibration position. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 179 Location of oil plugs on page 176 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 180 Turn axis-4 to the calibration position. DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 181 5 - 6 on page 128 Note If the robot is fitted in a suspended position, the wrist should be turned 180°. Refit the oil plugs. Tightening torque: • 10 Nm 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 182: Replacing Smb Battery
See Operating manual - IRC5 with FlexPendant for instructions. WARNING See instructions for batteries, WARNING - Safety risks during handling of batteries on page Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 183 The SMB battery is located at the base of the robot, as shown in the figure. DSQC 633A xx0800000322 SMB battery (2-pole battery contact) Battery cover Attachment screws SMB battery cable How to arrange the battery cable Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 184 Do not replace the battery contact! Equipment Note SMB battery pack Battery includes protection circuits. Replace it only with given spare part no. or an ABB approved equivalent. Spare part list on page 345. Standard toolkit Content is defined in section Standard tools on page 341.
Page 185 WARNING - The unit is sensitive to ESD! on page 53 Reconnect the battery cable to the SMB battery. See the figure in Location of SMB battery on page 183. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 186 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 187: Cleaning Activities
Perform according to section Cleaning with water and steam on page 187. Cleaning with water and steam Cleaning methods that can be used for ABB robots with protection Standard, Foundry Plus, Wash and Foundry Prime. Equipment, etc. Note Vacuum cleaner...
Page 188 Never point the water jet at connectors, joints, sealings, or gaskets! • Never use compressed air to clean the robot! • Never use solvents that are not approved by ABB to clean the robot! • Never spray from a distance closer than 0.4 meters! •...
Page 189: Repair
If the IRB 4600 is connected to power, always make sure that the IRB 4600 is connected to earth before starting any repair work. For more information see: • Product manual - IRC5 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 190: General Procedures
The test is complete. Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 191: Mounting Instructions For Bearings
• During operation, the bearing should be filled to 70-80% of the available volume. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 192 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. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 193: Mounting Instructions For Seals
Mount the seal correctly with a mounting tool. Never hammer directly on the seal as this may result in leakage. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 194 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 195: Complete Robot
Removing the SMB unit on page 224 • Brake release unit Removing the brake release unit on page 229 • Motors Removing motors on page 278 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 196 The location of the cable harness in the base, frame and lower arm is shown in the figures. Cable harness, base and frame. xx0900000009 Cover base Bracket Cable harness Axis-1 motor cable Axis-2 motor cable Axis-2 motor Axis-1 motor Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 197 Other tools and procedures may be re- These procedures include references to the quired. See references to these procedures tools required. in the step-by-step instructions below. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 198 • E: R1.SMB Remove the cover base. xx0800000456 A Base B Cover base C Attachment screws Disconnect connectors on the brake release unit: • • • Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 199 A Thin nut, width 30 mm B R1.SMB C Bracket D Air connector Unscrew the nut for the air connection on the inside of the bracket. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 200 Remove the SMB unit from its attachment How to remove the SMB unit is described screws. in section: • Removing the SMB unit on page 224 Leave the screws in the base. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 201 Disconnect the screen connections of: • R1.SMB1-2 • R1.SMB2-6 xx0900000035 Parts: • A: Screen connection (4 pcs) Disconnect the earth cables. xx0900000015 Parts: • A: Earth • B: Distance screws Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 202 Continue removal of the cable package from How to remove the cable package from the frame. the frame is described in section • Removing cable harness in frame on page 203 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 203 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) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 204 Cut the cable strap on the lower arm. See the figure in: • Location of the cable harness on page 196 (Cable harness, lower arm) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 205 C: Bracket, armhouse • D: Cable bracket Remove the bracket on the armhouse. xx0800000335 Parts: • A: Tubular shaft unit • B: Attachment screws • C: Bracket, armhouse Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 206 How to remove the motor cables from the by disconnecting the motor cables of the axis-3, axis-4, axis-5 and axis-6 motors axis-3, axis-4, axis-5 and axis-6 motors. see section: • Removing motors on page 278 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 207: Refitting The Complete Cable Harness
Refitting the SMB unit on page 226 • Brake release unit Refitting the brake release unit on page 230 • Motors Refitting motors on page 286 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 208 The location of the cable harness in the base, frame and lower arm is shown in the figures. Cable harness, base and frame. xx0900000009 Cover base Bracket Cable harness Axis-1 motor cable Axis-2 motor cable Axis-2 motor Axis-1 motor Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 209 Other tools and procedures may be re- These procedures include references to the quired. See references to these procedures tools required. in the step-by-step instructions below. Cable grease Shell Alvania WR2 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 210 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) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 211 Note Use caution when performing this procedure in order not to damage cables or other components! Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 212 • C: Cover Connect the axis-1 and axis-2 motor cables. How to refit the motor cables is described in section: • Refitting motors on page 286 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 213 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 214 Valid for other design than Type C. Attach the cable harness to the bracket. xx0900000098 Parts: • A: Attachment screw and nut • B: Bracket • C: Cable harness Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 215 • R1.SMB3-6 • R2.SMB Refit the SMB unit. How to refit the SMB unit is described in section: • Refitting the SMB unit on page 226 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 216 B: Base Before refitting the connectors on the bracket, arrange cables and connectors as shown in the figure. xx1200000857 A R1.CP/CS B R1.MP C Air hose Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 217 Secure the bracket on the distance screws. xx1200000887 A Base B Distance screw C Attachment screw D Bracket Reconnect connectors on the brake release unit: • • • Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 218 Check that there is no leakage from the air hose. Reconnect the battery cable. Secure the battery cable with cable straps. xx0900000099 Parts: • A: Cable straps (2 pcs) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 219 Before starting this procedure, first refit the cable harness in the frame and base. See: • Refitting the complete cable harness on page 207 • Refitting the complete cable harness on page 207 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 220 • Location of the cable harness on page 208 (Cable harness, lower arm) Push the cable harness carefully into the armhouse. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 221 319. WARNING The cover on the armhouse must be fitted when the robot is running. It is a vital part for the stability of the robot. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 222 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 223: Replacing Smb Unit
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! Equipment Note Standard toolkit Content is defined in section Standard tools on page 341. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 224 A: Attachment screws (6 pcs) • B: Base cover • C: Cable straps, securing the bat- tery cable (2 pcs) Cut the cable straps securing the battery cable. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 225 SMB unit just enough to be able to re- • Location of SMB unit on page 223 move the SMB unit. Remove the SMB unit. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 226 • Location of SMB unit on page 223 Note Use caution when performing this procedure order not to damage cables or other com- ponents! Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 227 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 228: Replacing The Brake Release Unit
The connectors X8, X9 and X10 are placed on the push-button unit as shown in the figure below. xx0300000201 Required equipment Equipment Note Standard toolkit Content is defined in section Standard tools on page 341. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 229 Remove the nuts securing the brake release See the figure in: unit. • Location of brake release unit on page 228 Remove the brake release unit. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 230 How to check and fix the brake release jammed. buttons if jammed, is described in sec- tion: • WARNING - The brake release buttons may be jammed after service work on page 51 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 231 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 232: Replacing The Base
Base Frame Lower arm Armhouse (part of Upper arm complete) Tubular shaft unit (part of Upper arm complete) Wrist unit (part of Upper arm complete) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 233 These procedures include references to the quired. See references to these procedures tools required. in the step-by-step instructions below. Loctite 7063 For cleaning. Loctite 574 For sealing. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 234 Wrap up the cabling against the frame to • Removing cable harness in lower keep it undamaged during the remaining arm and armhouse on page 204 work. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 235 This will make the upper and lower arms move in a dangerous way and can cause serious personal injury or mechanical dam- age to the robot. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 236 It is important to secure the robot properly on the loading pallet. Small movements can make the robot alter its position, which can cause personal injury or mechanical damage. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 237 The robot base weighs 60 kg. All lifting accessories used must be sized accordingly! Secure the base of the robot with round- slings in an overhead crane or similar. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 238 Remove residues of old Loctite and other contaminations from surfaces before apply- ing new Loctite 574. Use Loctite 7063 (or similar) for cleaning. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 239 Secure the base with a roundsling in an overhead crane or similar and lift it to the mounting site. Apply guide pins in opposite holes in the axis-1 gearbox. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 240 Apply some grease to the o-ring and refit the o-ring between the cover and base. Refit the cover plate at the bottom of the base with its attachment screws. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 241 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 242: Upper Arm
The upper complete arm is located as shown in the figure. xx1200000635 Upper arm Lower arm Washer (3 pcs) xx1200000520 Attachment screws M10x40 quality steel 12.9 Gleitmo (15 pcs) Axis-3 gearbox Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 243 40/2.50, -20/2.55 on page 352 Tubular shaft unit For spare part no. see chapter Spare parts, sec- tion: • Upper arm IRB 4600-60/2.05, -40/2.05- 40/2.50, -20/2.55 on page 352 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 244 Note Run the robot to the position shown in the figure. The robot must be floor mounted and the upper arm must be horizontally positioned. xx0800000336 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 245 Disconnect all motor cables from motors How to disconnect cables from motors is axes 3, 4, 5 and 6. detailed in sections: • Removing motors on page 278 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 246 • Location of the complete upper arm on page 242 Note Do not remove the attachment screws securing the gearbox axis 3 to the arm- house! Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 247 Attaching the roundslings to the upper sides of the screws and fasten the arm on page 248. free end of the roundsling to the lifting hook. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 248 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 249 Refit the cable bracket with its attachment screws. Reconnect all motor cables. How to connect motor cables is detailed in sections: • Refitting motors on page 286 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 250 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 251: Replacing Complete Tubular Shaft Unit
Other tools and procedures may be re- These procedures include references to the tools quired. See references to these proced- required. ures in the step-by-step instructions be- low. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 252 Remove motors axes 4, 5 and 6. How to remove motors is described in section: • Removing motors on page 278 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 253 Do not damage the gears when removing on page 251. the tubular shaft unit. CAUTION Remaining oil will drain out from the gear- box cavity when the tubular shaft is lifted out. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 254 C Tubular shaft unit D Cylindrical pin (2 pcs) CAUTION The robot arm tube weighs 65 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 255 If the wrist unit has been removed from the How to refit the wrist unit is detailed in tubular shaft unit, refit it now. section: • Refitting of wrist unit on page 259 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 256 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 257: Replacing Wrist Unit
Upper arm Gear O-ring sealing plate Wrist unit Spring washer, conical 8.4x18x2, quality steel-mZn12c (7 pcs) Attachment screw M8x40, quality steel 12.9 Gleitmo (7 pcs) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 258 341. Other tools and procedures may be required. These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 259 Not applicable to variant IRB 4600-20/2.50. Fit See the figure in: the o-ring sealing plate. • Location of wrist unit on page 257 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 260 Measuring the play, axis 5 on page 262 • Measuring the play, axis 6 on page 265 Perform a leak-down test. Performing a leak-down test on page 190. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 261 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 262: Measuring The Play, Axis
Move the robot to calibration position and turn the axis 4 90°. Fit the measuring tool, play to the turning Art. no. is specified in Required equip- disk. ment on page 262. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 263 C: 100 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 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 265: Measuring The Play, Axis 6
Fit the measuring tool, play to the turning Art. no. is specified in Required equipment disk. on page 265. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 266 A: Mearuring tool, play • B: 100 mm • C: 150 mm • F: 40N Remove the load and set the dial indicat- or to zero. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 267 (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: 0.22 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 268: Lower Arm
4.5.1 Replacing the lower arm Location of lower arm Type C The lower arm is located as shown in the figure. xx1200000636 Upper arm Axis-3 gearbox Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 269 Attachment screws M12x50 quality Steel 12.9 Gleitmo (18 pcs) Other design than Type C The lower arm is located as shown in the figure. xx0800000360 Upper arm Axis-3 gearbox Lower arm Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 270 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 271 C, but the principle of fitting the lifting lug is the same on Type C. xx0800000379 Parts: • A: Lifting lug Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 272 CAUTION The robot lower arm weighs 65 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 273 E: Attachment screws M12x50 quality steel Gleitmo 12.9 (18 pcs) Secure the complete upper arm with round- slings in an overhead crane and lift it to the robot. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 274 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 275: Frame And Base
For spare part no. see chapter Spare parts, section: • Lower arm and frame on page 350 Standard toolkit Content is defined in section Standard tools on page 341. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 276 Fit the two o-rings on the stop pin. See the figure in • Location of stop pin axis 1 on page 275 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 277 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 278: Motors
Attachment screws, axis-2 motor (4 pcs) + washers. See Tightening torques and attachment screws on page 290 Connection box Axis-1 motor Axis-2 motor O-ring Hole Cable gland cover Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 279 Attachment screws, axis-4, axis-5 and axis-6 motors (3x4 pcs) + washers. Tightening torques and attachment screws on page 290 Axis-3 motor Axis-4 motor Axis-5 motor Axis-6 motor O-ring (axis-4, axis-5 and axis-6) Armhouse Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 280 Weight in kg Axis-1 motor 13 kg Axis-2 motor 25 kg Axis-3 motor 13 kg Axis-4 motor 8 kg Axis-5 motor 8 kg Axis-6 motor 8 kg Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 281 Note Draining of gearbox is only needed when removing the axes 2 and 3 motors. Action Note Axis-1 motor: • Draining of gearbox is not needed. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 284 If required, press the motor out of position by Note fitting two screws in the threaded holes in the motor flange. Always use removal tools in pairs diag- onal to each other. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 285 See the figure in: • Location of axis-1 and axis-2 Check that the o-ring also is removed. It might motors on page 278 stay in the armhouse when the motor is re- moved. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 286: Refitting Motors
Location of axis-3, axis-4, axis-5 and axis-6 motors The axis-3, axis-4, axis-5 and axis-6 motors are located as shown in the figures. Motors: (3) = Axis-3 motor Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 287 Attachment screws, axis-4, axis-5 and axis-6 motors, (3x4 pcs) + washers. See Tightening torques and attachment screws on page 290 Axis-3 motor Axis-4 motor Axis-5 motor Axis-6 motor O-ring (axis-4, axis-5 and axis-6) Armhouse Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 288 The motors for the different axes weighs according to the table: Motor Weight in kg Axis-1 motor 13 kg Axis-2 motor 25 kg Axis-3 motor 13 kg Axis-4 motor 8 kg Axis-5 motor 8 kg Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 289 Use this procedure to fill oil in gearbox, if needed. Note Filling oil in the gearbox is only needed when refitting motors axes 2 and 3. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 290 Motor axis 3 Flange thickness Attachment screws Flange thickness Attachment screws 18.5 mm M10x40 15 mm M8x35 16 mm M10x35 13 mm M8x30 xx0900000443 Flange thickness Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 291 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. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 292 Check that the wire exit holes of motor axis 3 are in the correct position. See illustration! xx0900000300 Parts: • A: Wire exit holes, motor axis 3 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 293 Location of axis-1 and axis-2 Refit the connection box (if it has been re- motors on page 286 moved). Note Make sure that the o-ring is in place! Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 294 Only applicable to motors axes 3, 4, 5 and 6! If the gasket is damaged, it need to be replaced. Check that the gasket on the cover on the armhouse is intact. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 295 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 296: Adjusting The Play Of Axis 4, 5 And 6 Motors
6 within this range. Push or tap the motor in radial direction so that the play becomes minimal within one motor turn, without the gear "chewing". 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 297: Gearboxes
233. Type C xx1200000637 Frame Radial sealing Axis-1 gearbox with O-ring Harness pipe Washer (16 pcs) Attachment screws M10x100 quality Steel 12.9 Gleitmo (16 pcs) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 298 Other tools and procedures may be re- These procedures include references to the quired. See references to these procedures tools required. in the step-by-step instructions below. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 299 C: Uppermost attachment hole for securing the base • D: Gearbox axis 1 CAUTION The gearbox weighs 27 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 300 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 301 Remove any painting from the assembly surfaces, with a knife. Fit guide pins into two of the holes for the Always use guide pins in pairs! attachment screws. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 302 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 303: Replacing Gearbox Axis 2
Attachment screws M12x50 quality Steel 12.9 Gleitmo (15 pcs) Washers (15 pcs) Gearbox axis 2 O-ring Frame Required equipment Equipment Art. no. Note Rotation tool 3HAB7887-1 Lifting accessories Roundslings. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 304 Move the robot to the position shown The figure shows IRB 2600 but the position of in the figure. the robot is correct. Upper arm should rest on the axis-3 damper. xx1200000068 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 305 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 306 Make sure not to damage the cables or the cable brackets on the robot. CAUTION The gearbox weighs 51 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 307 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 308 Fit two guide pins in opposite holes in the frame. Secure the gearbox with a roundsling in an overhead crane or similar. Release the brakes of the axis 2 motor. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 309 A: Frame • B: Gearbox axis 2 • C: Lower arm • D: Washer (18 pcs) • E: Attachment screws M12x50 quality 12.9 steel Gleitmo (18 pcs) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 310 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 311: Replacing Gearbox Axis 3
The gearbox is located as shown in the figure. Type C xx1200000638 Upper arm Axis-3 gearbox Washers (16 pcs) Attachment screws M10x50 quality Steel 12.9 Gleitmo (16 pcs) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 312 Used to guide the gearbox and the upper arm during removal/refitting. Rotation tool 3HAB7887-1 Standard toolkit Content is defined in section Standard tools on page 341. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 313 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 314 Do not remove the attachment screws se- curing the gearbox axis 3 to the armhouse! CAUTION The robot upper arm weighs 140 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 315 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 316 Specified in Required equipment on page 312. Move the upper arm to its mounting posi- tion. (With the brakes of the axis 3 motor still re- leased.) Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 317 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 318 This page is intentionally left blank...
Page 319: Calibration
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in the section Calibration methods on page 320 , and further detailed in separate calibration manuals.
Page 320: Calibration Methods
To regain 100% absolute accuracy perform- ance, the robot must be recalibrated for abso- lute accuracy! xx0400001197 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 321 Calibration Pendulum - standard method Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.
Page 322: Calibration Scale And Correct Axis Position
The figures show the calibration scales positions for all the robot variants. IRB 4600 - 60/2.05, -45/2.05, 40/2.55, -20/2.50 xx0800000312 Calibration mark, axis 1 Calibration mark, axis 2 Calibration mark, axis 3 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 323 5.3 Calibration scale and correct axis position Continued IRB 4600 - 60/2.05, -45/2.05, 40/2.55 xx0800000313 Calibration mark, axis 4 Calibration mark, axis 5 Calibration mark, axis 6 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 324 5 Calibration 5.3 Calibration scale and correct axis position Continued IRB 4600 -20/2.50 xx0800000320 Calibration mark, axis 4 Calibration mark, axis 5 IRB 4600 -20/2.50 xx0800000321 Calibration mark, axis 6 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 325: Calibration Movement Directions For All 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 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 326: Updating Revolution Counters
Use this procedure to store the revolution counter setting with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. All mechanical units connected to the system are shown with their calibration status. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 327 If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi- tioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. See Checking the calibration position on page 328. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 328: Checking The Calibration Position
Check that the calibration marks for the Calibration scale and correct axis pos- axes align correctly. If they do not, update ition on page 322, and Updating revolution the revolution counters! counters on page 326. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 329: Decommissioning
These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 330: Environmental Information
Also note that: • Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 331: Robot Description
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. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
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Page 333: Reference Information
8 Reference information 8.1 Introduction 8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 334: Applicable Safety Standards
Safety of machinery - General requirements for the design and construction of fixed and movable guards Other standards Standard Description ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 335 8.2 Applicable safety standards Continued Standard Description ANSI/UL 1740 Safety standard for robots and robotic equipment (option 429-1) CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require- ments (option 429-1) 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 336: Unit Conversion
3.28 ft. 39.37 in Weight 1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 337: Screw Joints
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
Page 338 Molycote 1000, Gleitmo 603 or equivalent with allen head screws. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 339 The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 340: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 341: Standard Tools
Socket head cap no: 5, socket 1/2" bit L 20 mm Socket head cap no: 6, socket 1/2" bit L 20 mm Socket head cap no: 8, socket 1/2" bit L 20 mm Small cutting plier T-handle with ball head 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 342: Special Tools
Calibration tool ax1 3HAC13908-4 Levelmeter 2000 kit 6369901-347 Includes one sensor. Measuring pin 3HAC13908-5 Sensor fixture 68080011-GM Sensor plate 3HAC0392-1 Sync. adapter 3HAC13908-1 Turn disk fixture 3HAC68080011-GU Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 343 Description Article no. Note Lifting accessory, axis 2 Lifting accessory, axis 3 Rotating lifting point 2 pcs For lifting of upper arm. Dimension: M8. Example: Gunnebo RLP GrabiQ M8-10. xx1100000564 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 344: Lifting Accessories And Lifting Instructions
The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. This implies that the instructions delivered with the lifting accessories should be stored for later reference. 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 345: Spare Part List
The table shows which wrist unit can be used on which variant. Variant Wrist unit 3HAC029030-004 Wrist unit 3HAB9398-1 IRB 4600-60/2.05 IRB 4600-45/2.05 IRB 4600-40/2.55 IRB 4600-20/2.50 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 346 The table shows which motor unit can be used on which wrist variant when converting to or from a IRB 4600-20/2.5. Variant Motor unit 3HAC029034-004 Motor unit 3HAC030211-001 IRB 4600-60/2.05 IRB 4600-45/2.05 IRB 4600-40/2.55 IRB 4600-20/2.50 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 347: Base Cover Assembly
Type C: 3HAC038465-001 O-ring (3 pcs) Other design than Type C 21522012-428 O-Ring (3 pcs) Illustration, base cover assembly Link to Spare parts, base cover assembly on page 347 xx1300000188 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 348: Base And Frame Unit
V-ring (not shown in the figure) 3HAB3732-23 O-ring (not shown in the figure) 3HAB3772-35 Flange sealing (Loctite 574) 3HAC042474-001 Cable protection (not shown in the figure) 3HAC027499-004 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 349 9 Spare part list 9.3 Base and frame unit Continued Illustration base and frame unit Link to Spare parts, base and frame unit on page 348 xx1300000203 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 350: Lower Arm And Frame
3HAC030817-006 Lower arm (IRB 4600-40/2.55, -20/2.50) 3HAC031002-005 Damper 3HAC029243-001 Plug IF3820 S06-EXT 3HAC033192-001 Lubricating oil See section Type of lubrica- tion in gearboxes on page 148. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 351 9 Spare part list 9.4 Lower arm and frame Continued Illustration, lower arm and frame Link to Spare parts list, lower arm and frame on page 350 xx1300000189 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 352: Upper Arm Irb 4600-60/2.05, -40/2.05-40/2.50, -20/2.55
Illustration upper arm -20/2.50 on page 355 Upper arm parts Spare parts no. Type C: 3HAC042870-005 Arm housing Other design than Type C: 3HAC028633-004 Arm housing Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 353 Type and amount of oil is detailed in a separate manual, Technical reference manual - Lubrication in gearboxes, also see information in section Type of lubrication in gearboxes on page 148. Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 354 9 Spare part list 9.5 Upper arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55 Continued Illustration upper arm -60/2.05, -45/2.05 Link to Spare parts, upper arm -60/2.05, -45/2.05 on page 352 xx0800000317 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 355 9 Spare part list 9.5 Upper arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55 Continued Illustration upper arm -20/2.50 Link to Spare parts, upper arm -20/2.50 on page 352 xx0800000358 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 356 9 Spare part list 9.5 Upper arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55 Continued Illustration upper arm -40/2.55 Link to Spare parts, upper arm -40/2.55 on page 352 xx0800000364 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 357 9 Spare part list 9.5 Upper arm IRB 4600-60/2.05, -40/2.05-40/2.50, -20/2.55 Continued Illustration cover arm housing Link to Spare parts, cover arm housing on page 353 xx0800000375 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 358: Wrist Unit (60 Kg/45 Kg/20 Kg)
Complete wrist 12/20 kg on page 358 Wrist parts Spare parts no. Wrist complete 3HAB9398-1 Complete wrist 20 kg Wrist parts Spare parts no. Wrist complete 3HAC7101-4 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 359 9.6 Wrist unit (60 kg/45 kg/20 kg) Continued Illustration wrist unit, 60 kg Link to Spare parts wrist 60 kg /45 kg on page 358 xx0800000318 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 360 9.6 Wrist unit (60 kg/45 kg/20 kg) Continued Illustration wrist 12/20 kg Wrist 12/20 kg is used on variant IRB 4600-20/2.50. Link to Complete wrist 12/20 kg on page 358 xx0800000369 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 361: Electrical Connections
Battery pack (3-pole battery contact) 3HAC044075-001 Lithium Can only be used with SMB board 3HAC044168-001. Serial measurement board, DSQC 633A 3HAC031851-001 Serial measurement board, RMU 101 3HAC044168-001 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 362 3HAC16831-1. Serial measurement unit 3HAC046277-001 Contains serial measure- ment board 3HAC044168-001 and battery pack 3HAC044075-001. Signal cable SMB 3HAC4050-1 SMB replacement set 3HAC046686-001 Illustration electrical connections xx1300000258 DSQC 663A xx1300000342 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 363: Gearboxes
Type C Axis-1, o-ring 3HAB3772-149 Axis-1, o-ring 3HAB3772-128 Axis-1, oil plug gasket 3HAC029646-001 Axis-2, o-ring 3HAB3772-120 Axis-2, oil plug gasket 3HAC029646-001 Axis-3, o-ring 3HAB3772-129 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 365: Motors
Axis 6 3HAC030211-004 O-rings Motor Spare parts no. Axis 1 3HAB3772-107 Axis 2 3HAB3772-107 Axis 3 3HAB3772-107 Axis 4 3HAB3772-102 Axis 5 3HAB3772-102 Axis 6 3HAB3772-102 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 367: Labels
ABB-logotype (dimension 150x60 mm) 3HAC5089-1 Foundry Plus-logotype 3HAC7835-1 Oil label (Kyodo Yushi TMO 150) 3HAC032726-001 1 pc Oil label (Optimol Optigear BM 100) 3HAC034752-001 1 pc Label-Oil quality 3HAC039765-001 1 pc 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 368: Options
(Suspended position) 239-1 CP/CS Proc1, base 3HAC16667-1 28-1 Working range limit, axis 1 3HAC033134-001 Connector set on base 3HAC033181-001 Connector set R2.CP/R2.CS 3HAC025396-001 Additional mechanical stop set, axis 1 3HAC033134-001 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 369: Circuit Diagram
3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6620 3HAC025090-001 Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Continues on next page 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 370 Circuit diagram - IRB 6640 3HAC025744-001 Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6660 3HAC025744-001 3HAC029940-001 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 371 98 axis 1, floor mounted robots, 150 expected life, 113 axis 1, suspended robots, 156 axis 2, 162 axis 3, 166 fence dimensions, 32 axis 4, 172 fire extinguishing, 33 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 372 25 weight hydraulic system, 27 robot, 67, 75, 235, 237, 239, 241, 245, 249, 253–254, installation, 22 259–260, 270, 272, 299, 302, 306, 308, 314–316, 340 oil change, 55 3HAC033453-001 Revision: H © Copyright 2009-2013 ABB. All rights reserved.
Page 374 Telephone +46 (0) 21 344 400 ABB AS, Robotics Discrete Automation and Motion Box 265 N-4349 BRYNE, Norway Telephone: +47 51489000 ABB Engineering (Shanghai) Ltd. 5 Lane 369, ChuangYe Road KangQiao Town, PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 www.abb.com/robotics...

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