Irb 4600

ROBOTICS
Product manual
IRB 4600
Trace back information:
Workspace R17-2 version a11
Checked in 2017-09-20
Skribenta version 5.1.011
Product manual
IRB 4600 - 60/2.05
IRB 4600 - 45/2.05
IRB 4600 - 40/2.55
IRB 4600 - 20/2.50
IRC5
Document ID: 3HAC033453-001

Revision: Q
© Copyright 2009-2017 ABB. All rights reserved.

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

ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden
Table of contents
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation, IRC5 .......................................................................................................... 17
How to read the product manual ...................................................................................................... 19
1 Safety 21
1.1 Introduction to safety information ......................................................................... 21
1.2 General safety information .................................................................................. 22
1.2.1 Introduction to general safety information .................................................... 22
1.2.2 Safety in the robot system ........................................................................ 23
1.2.3 Protective stop and emergency stop ........................................................... 25
1.2.4 Safety risks ............................................................................................ 26
1.2.4.1 Safety risks during installation and service work on manipulators ......... 26
1.2.4.2 CAUTION - Hot parts may cause burns! ........................................... 29
1.2.4.3 Safety risks related to tools/work pieces .......................................... 30
1.2.4.4 Safety risks related to pneumatic/hydraulic systems .......................... 31
1.2.4.5 Safety risks with pressure relief valve .............................................. 32
1.2.4.6 Safety risks during operational disturbances ..................................... 33
1.2.4.7 Risks associated with live electric parts ........................................... 34
1.2.5 Safety actions ......................................................................................... 36
1.2.5.1 Safety fence dimensions ............................................................... 36
1.2.5.2 Fire extinguishing ........................................................................ 37
1.2.5.3 Emergency release of the robot arm ............................................... 38
1.2.5.4 Brake testing .............................................................................. 39
1.2.5.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 40
1.2.5.6 Enabling device and hold-to-run functionality .................................... 41
1.2.5.7 Work inside the working range of the robot ....................................... 42
1.2.5.8 Signal lamp (optional) ................................................................... 43
1.3 Safety signals and symbols ................................................................................. 44
1.3.1 Safety signals in the manual ...................................................................... 44
1.3.2 Safety symbols on product labels ............................................................... 46
1.4 Safety related instructions .................................................................................. 52
1.4.1 DANGER - Moving robots are potentially lethal! ............................................ 52
1.4.2 DANGER - First test run may cause injury or damage! ................................... 53
1.4.3 WARNING - The brake release buttons may be jammed after service work ........ 54
1.4.4 DANGER - Make sure that the main power has been switched off! .................... 55
1.4.5 WARNING - The unit is sensitive to ESD! ..................................................... 57
1.4.6 WARNING - Safety risks during handling of batteries ..................................... 59
1.4.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ...... 60
2 Installation and commissioning 63

2.1 Introduction ...................................................................................................... 63
2.2 Unpacking ....................................................................................................... 64
2.2.1 Pre-installation procedure ......................................................................... 64
2.2.2 Working range and type of motion .............................................................. 68
2.2.3 Risk of tipping/stability ............................................................................. 72
2.3 On-site installation ............................................................................................ 73
2.3.1 Lifting robot with roundslings .................................................................... 73
2.3.2 Lifting and turning a suspended mounted robot ............................................ 76
2.3.3 Manually releasing the brakes ................................................................... 77
2.3.4 Orienting and securing the robot ................................................................ 80
2.3.5 Setting the system parameters for a suspended or tilted robot ......................... 84
2.3.6 Fitting equipment on robot ........................................................................ 88
2.3.7 Loads fitted to the robot, stopping time and braking distances ......................... 95
2.3.8 Installation of signal lamp (option) .............................................................. 96
2.4 Restricting the working range .............................................................................. 97
2.4.1 Axes with restricted working range ............................................................. 97
Product manual - IRB 4600 5

3HAC033453-001 Revision: Q
Table of contents
2.4.2 Mechanically restricting the working range of axis 1 ...................................... 98

2.5 Installing options ............................................................................................... 101
2.5.1 Installation of cooling fan for motors (option) ................................................ 101
2.5.2 Installation of Foundry Plus Cable guard (option no. 908-1) ............................. 108
2.5.3 Installing an expansion container ............................................................... 109
2.6 Robot in hot environments .................................................................................. 112
2.6.1 Start of robot in hot environments .............................................................. 112
2.7 Robot in cold environments ................................................................................. 113
2.7.1 Start of robot in cold environments ............................................................ 113
2.8 Electrical connections ........................................................................................ 114
2.8.1 Robot cabling and connection points .......................................................... 114
2.8.2 Customer connection on robot ................................................................... 117
2.8.3 Customer connections on upper arm .......................................................... 119
3 Maintenance 121
3.1 Introduction ...................................................................................................... 121
3.2 Maintenance schedule ....................................................................................... 122
3.2.1 Specification of maintenance intervals ........................................................ 122
3.2.2 Maintenance schedule ............................................................................. 123
3.2.3 Expected component life ......................................................................... 125
3.3 Inspection activities ........................................................................................... 126
3.3.1 Inspecting oil level, axis 1 gearbox ............................................................. 126
3.3.2 Inspecting the oil level, axis 2 gearbox ........................................................ 133
3.3.5 Inspecting oil level, gearbox axes 5 - 6 ........................................................ 140
3.3.6 Inspecting the cable harness ..................................................................... 144
3.3.7 Inspecting information labels ..................................................................... 146
3.3.8 Inspecting the mechanical stop pin, axis 1 ................................................... 149
3.3.9 Inspecting additional mechanical stops ....................................................... 152
3.3.10 Inspecting dampers ................................................................................. 154
3.3.11 Inspecting the pressure relief valve ............................................................ 156
3.3.12 Inspecting Signal lamp (option) .................................................................. 158
3.4 Replacement activities ....................................................................................... 160
3.4.1 Type of lubrication in gearboxes ................................................................ 160
3.4.2 Changing the oil, axis-1 gearbox on floor mounted robots ............................... 162
3.4.3 Changing the oil, axis-1 gearbox on suspended robots ................................... 168
3.4.4 Changing the oil, axis-2 gearbox ................................................................ 174
3.4.7 Changing oil, axes-5 and -6 gearboxes ........................................................ 189
3.4.8 Replacing SMB battery ............................................................................. 195
3.5 Cleaning activities ............................................................................................. 200
3.5.1 Cleaning the IRB 4600 .............................................................................. 200
4 Repair 203
4.1 Introduction ...................................................................................................... 203
4.2 General procedures ........................................................................................... 204
4.2.1 Performing a leak-down test ...................................................................... 204
4.2.2 Mounting instructions for bearings ............................................................. 205
4.2.3 Mounting instructions for seals .................................................................. 207
4.3 Complete robot ................................................................................................. 209
4.3.1 Removing the complete cable harness ........................................................ 209
4.3.2 Refitting the complete cable harness .......................................................... 222
4.3.3 Replacing SMB unit ................................................................................. 238
4.3.4 Replacing the brake release board ............................................................. 244
4.3.5 Replacing the base .................................................................................. 249
4.4 Upper arm ....................................................................................................... 259
4.4.1 Replacing the complete upper arm ............................................................. 259
6 Product manual - IRB 4600

Table of contents
4.4.2 Replacing complete tubular shaft unit ......................................................... 269

4.4.3 Replacing wrist unit ................................................................................. 275
4.4.4 Measuring the play, axis 5 ......................................................................... 282
4.4.5 Measuring the play, axis 6 ......................................................................... 285
4.5 Lower arm ....................................................................................................... 288
4.5.1 Replacing the lower arm ........................................................................... 288
4.6 Frame and base ................................................................................................ 295
4.6.1 Replacing stop pin axis 1 .......................................................................... 295
4.7 Motors ............................................................................................................ 298
4.7.1 Removing motors .................................................................................... 298
4.7.2 Refitting motors ...................................................................................... 306
4.7.3 Adjusting the play of axis 4, 5 and 6 motors ................................................. 316
4.8 Gearboxes ....................................................................................................... 317
4.8.1 Replacing gearbox axis 1 .......................................................................... 317
5 Calibration 341
5.1 Introduction to calibration ................................................................................... 341
5.1.1 Introduction and calibration terminology ...................................................... 341
5.1.2 Calibration methods ................................................................................. 342
5.1.3 When to calibrate ................................................................................... 344
5.2 Synchronization marks and axis movement directions ............................................. 345
5.2.1 Synchronization marks and synchronization position for axes ......................... 345
5.2.2 Calibration movement directions for all axes ................................................ 348
5.3 Updating revolution counters ............................................................................... 349
5.4 Calibrating with Axis Calibration method ............................................................... 353
5.4.1 Description of Axis Calibration .................................................................. 353
5.4.2 Calibration tools for Axis Calibration ........................................................... 355
5.4.3 Installation locations for the calibration tools ............................................... 357
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 360
5.5 Calibrating with Calibration Pendulum method ........................................................ 367
5.6 Verifying the calibration ...................................................................................... 368
5.7 Checking the synchronization position .................................................................. 369
6 Decommissioning 371
6.1 Introduction ...................................................................................................... 371
6.2 Environmental information .................................................................................. 372
6.3 Scrapping of robot ............................................................................................. 373
7 Robot description 375

7.1 Type C of IRB 4600 ............................................................................................ 375
8 Reference information 377

8.1 Introduction ...................................................................................................... 377
8.2 Applicable standards ......................................................................................... 378
8.3 Unit conversion ................................................................................................. 380
8.4 Screw joints .................................................................................................... 381
8.5 Weight specifications ......................................................................................... 384
8.6 Standard tools .................................................................................................. 385
8.7 Special tools .................................................................................................... 386
8.8 Lifting accessories and lifting instructions .............................................................. 389
9 Spare part lists 391

9.1 Spare part lists and illustrations ........................................................................... 391

Table of contents
10 Circuit diagram 393

10.1 Circuit diagrams ................................................................................................ 393
Index 395

Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The robot described in this manual has the protection type Standard and Foundry
Plus.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety Safety information that must be read through before performing
any installation or service work on the robot. Contains general
safety aspects as well as more specific information on how to
avoid personal injuries and damage to the product.
Installation and commis- Required information about lifting and installation of the robot.
sioning
Maintenance Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration Calibration procedures and general information about calibration.
Decommissioning Environmental information about the robot and its components.
Continues on next page

Continued
Chapter Contents
Reference information Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards etc.
Spare part / part list Complete spare part list and complete list of robot components,
shown in exploded views.
Exploded views Detailed illustrations of the robot with reference numbers to the
part list.
Circuit diagram Reference to the circuit diagram for the robot..
References
Reference Document ID
Product manual - IRB 4600 Foundry Prime 3HAC040585-001
Product specification - IRB 4600 3HAC032885-001
Product manual, spare parts - IRB 4600 3HAC049108-001
Circuit diagram - IRB 4600 3HAC029038-003
Operating manual - General safety information i 3HAC031045-001
Product manual - IRC5 3HAC021313-001
IRC5 with main computer DSQC 639.
Product manual - IRC5 3HAC047136-001
IRC5 with main computer DSQC1000.
Operating manual - Emergency safety information 3HAC027098-001
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - Troubleshooting IRC5 3HAC020738-001
Operating manual - Calibration Pendulum 3HAC16578-1
Operating manual - Service Information System 3HAC050944-001
Technical reference manual - Lubrication in gearboxes 3HAC042927-001
Technical reference manual - System parameters 3HAC050948-001
Application manual - Additional axes and stand alone controller 3HAC051016-001
Application manual - Electronic Position Switches 3HAC050996-001
Application manual - CalibWare Field 5.0 3HAC030421-001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
Revision Description
- First edition

Continued
A The following updates have been made in this revision:
• New WARNING! added in Safety chapter section Work inside the working
range of the robot on page 42.
• New WARNING! added in Safety chapter section WARNING - Safety
risks during work with gearbox lubricants (oil or grease) on page 60.
• Information about the quality and used threadlength for attachment
screws on mounting flange, added in Installation chapter section Fitting
equipment on wrist and mounting flange on page 92.
• The text in the introduction to chapters Installation, Maintenance and
Repair has been updated concerning the robot being connected to earth
when power connected.
• Levelmeter calibration added in sections Brief description of calibration
methods on page 343 and Calibration equipment, Levelmeter (alternative
method) on page 386.
• Section Upper arm (2.05/2.50/2.55) in Spare parts updated with Type A
spare parts.
• Section Lifting and turning a suspended mounted robot on page 76 added
in Installation chapter.
• Section Installation of Foundry Plus Cable guard (option no. 908-1) on
page 108 added in Installation chapter.
• New DANGER! added in section Manually releasing the brakes on
page 77.
• Restricting working range with software added in section Mechanically
restricting the working range of axis 1 on page 98.
• The sections describing Replacing motors axes 1 through 6 has been
updated. Two new sections Removing motors on page 298 and Refitting
motors on page 306 replaces the older ones.
B The following updates have been made in this revision:
• Missing text "type A" for armhousing 3HAC034549-005 added in chapter
Spare parts section Upper arm (2.05/2.50/2.55).
• Wrist Foundry added in chapter Spare parts, section Wrist unit (20 kg
and 45/60kg.
• Motors in wrist as rebuilding parts added in section Rebuilding parts in
Spare parts IRB 4600.
• How to adjust the play on motors axes 4-6 and on wrist added in sections
Replacing motors, axes 4, 5 and 6 and Replacing wrist unit on page 275.
• Correction of required oil level, see Inspecting oil level, axis 1 gearbox
on page 126.
In chapter Safety :
• Updated safety signal graphics for levels Danger and Warning, see
Safety signals in the manual on page 44.
• New safety labels on the manipulators, see Safety symbols on product
labels on page 46.
• Revised teminology: robot replaced with manipulator.

Continued
C The following updates have been made in this revision:
• Added Installing an expansion container on page 109.
• A figure showing IRB 2600 removed in section Orienting and securing
the robot on page 80.
• Section Installation of Foundry Plus Cable guard (option no. 908-1) on
page 108 added.
• Updated the section Start of robot in cold environments on page 113.
• Interval for inspection of signal lamp added in section Maintenance
schedule on page 123.
• New design of frame added in sections Inspecting oil level, axis 1 gear-
box on page 126 and Changing the oil, axis-1 gearbox on floor mounted
robots on page 162.
• Figure showing required oil level added in section Inspecting oil level,
axis 1 gearbox on page 126.
• Inspection of oil level on suspended robot updated in section Inspecting
oil level, axis 1 gearbox on page 126.
D The following updates have been made in this revision:
• Added information about the bracket on the mechanical stop pin axis 1
has been updated in section Mechanically restricting the working range
of axis 1 on page 98, Inspecting the mechanical stop pin, axis 1 on
page 149 and Replacing stop pin axis 1 on page 295
• All information about Foundry Prime is removed from the manual. This
manual now only contains information for a 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 10.

Continued
E The following updates have been made in this revision:
• A new block, about general illustrations, added in section How to read
the product manual on page 19.
• Figure and describing text edited for the stress forces. Also, the actual
values of the stress forces are updated. See Loads on foundation, robot
on page 65.
• The difference in weight between the different robot variants is minor,
therefor the weight specification for the robot is simplified. See Weight,
robot on page 64.
• Removed Foundry from table with protection classes. See Protection
classes, robot on page 67.
• Additional information about software adjustments when suspending
robot, new section Setting the system parameters for a suspended or
tilted robot on page 84.
• Note about fan cabling added in the cable list. See Robot cabling and
connection points on page 114.
• Note about ambient temperature deleted from the maintenance schedule.
See Maintenance schedule on page 123.
• Changed information about the robot position when removing motor.
See Removing motors on page 298.
• Additional instructions for how to adjust the play of axes 4, 5 and 6 mo-
tors. See Adjusting the play of axis 4, 5 and 6 motors on page 316.
• Added step about removing/refitting axis 1 motor when replacing the
axis 1 gearbox. Also added information about guide pins. See Replacing
gearbox axis 1 on page 317. Also minor additions concerning the mating
of gearbox and motor, in all such instructions.
• New section about calibration movement directions for axes is added,
see Calibration movement directions for all axes on page 348.
• New section about how to perform a rough calibration of each robot axis
is added, see Updating revolution counters on page 349.
• New section about how to check the calibration position is added, see
Checking the synchronization position on page 369.
• Spare part number for tubular shaft unit is corrected, see Spare parts -
Upper arm.
• Additional information about lifting accessories and how to attach them
to the upper arm of the robot, see Attaching the lifting accessories to
the upper arm on page 264.
• Additional information in the procedure for replacing the base with im-
proved lifting instruction etc., see Replacing the base on page 249.
• Changed type of oil in axes 1, 3 and 4 gearboxes. See Type of lubrication
in gearboxes on page 160.

Continued
F The following updates have been made in this revision:
• Corrected measurement that belong to figure xx0300000187, when fitting
tools for measuring the play of axis 5, see Measuring the play, axis 5 on
page 282.
• Deleted the spare part number for harnesses in Spare parts - lower arm
and instead inserted a reference to the Electrical connections.
• Corrected the spare part numbers for cable harnesses, see Electrical
connections.
• Added information about releasing the motor brakes in order to set the
weight of different axes onto lifting accessories, see Replacing the
complete upper arm on page 259, Replacing gearbox axis 3 on page 333
and Replacing gearbox axis 2 on page 324.
• Changed the instruction for how to replace the axes 2 and 3 gearboxes
without having to remove the cable harness, see Replacing gearbox
axis 3 on page 333 and Replacing gearbox axis 2 on page 324.
• Added safety information about preventing roundslings from sliding
when lifting the upper arm tube, see Replacing complete tubular shaft
unit on page 269.
• Added information about removing painting, if any, from assembly sur-
faces when replacing gearboxes and motors.
• Added tip to speed up the draining of axis 4 gearbox, see Changing the
oil, axis-4 gearbox on page 185.
• Added information about o-ring and made other minor approvements to
the instruction for replacing wrist unit, see Replacing wrist unit on
page 275.
• Added information about disconnecting the battery cable when removing
the cable harness, see Removing the complete cable harness on page 209.
• Added a funnel to equipment list, see Changing the oil, axis-3 gearbox
on page 178.
• Added Profibus to the section about connections to extra equipment,
see Customer connection on robot on page 117.
• Some general tightening torques have been changed/added, see updated
values in Screw joints on page 381.
• The method of changing the axis-1 gearbox oil in suspended robots is
improved, see the new section Changing the oil, axis-1 gearbox on
suspended robots on page 168.
• Added spare part number for type B gearbox (axis 3), see Spare parts,
upper arm.
• Added WARNING - Safety risks during handling of batteries on page 59.
G The following updates have been made in this revision:
• Cable harness for Profibus is added to the spare part list, see Electrical
connections.
• Article number for guide sleeves is added.
• Information about the type and amount of oil has been removed from
the manual and can now be found in the Technical reference manu-
al - Lubrication in gearboxes, see References on page 10.
• Type C is added throughout the manual.
• Valid for other designs than type C: Information about oil plug sealing
washer on the axis-1 and axis-2 gearbox is changed. The spare part
number is added.
• A new SMB unit and battery is introduced, with longer battery lifetime.

Continued
H The following updates have been made in this revision:
• Spare part numbers are corrected for the lower arm, see Lower arm type
C and Rebuilding parts, and for motors, see Motors type C in Product
manual, spare parts - IRB 4600.
• 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 126.
J The following updates have been made in this revision:
• New article number for working range limit, axis 1 (Type C), is added in
spare parts.
• New article number for turning tool (Type C) is added in spare parts.
• Spare parts for electrical connections, cable harness, is updated.
• Instructions on how to fill oil in suspended robot is corrected, and article
number for oil change equipment is added to special tools.
• Amount of oil in axis-3 gearbox (Type C) is changed.
• Added information about risks when scrapping a decommissioned robot,
see Scrapping of robot on page 373.
• Spare parts and exploded views are not included in this document but
delivered as a separate document. See Product manual, spare parts - IRB
4600.
K The following updates have been made in this revision:
• Illustration changes in Dimension, mounting surface and guide bushing
on page 81.
• Term "Guide sleeves" changed to "Guide bushings", see Dimension,
mounting surface and guide bushing on page 81.
• A new WARNING! is added in the section about motor replacement, in-
forming not to mix different motor types.
• Minor corrections.
L The following updates have been made in this revision:
• Added values for restricted working range if the robot is equipped with
a gearbox Type C, see Mechanically restricting the working range of
axis 1 on page 98.
• Information about removing the mech stop bracket added in section
Axes with restricted working range on page 97.
M The following updates have been made in this revision:
• Turning disk fixture is removed from special tools for Levelmeter calib-
ration.
• Oil levels adjusted.
• Information about grounding and bonding point added, see Robot cabling
and connection points on page 114.
N Published in release R16.2. The following updates are made in this revision:
• Corrections due to updates in terminology.
• New dimensional drawing of the turning disk added to Fitting equipment
on wrist and mounting flange on page 92.
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 341.
• Information about grounding point added. See Robot cabling and con-
nection points on page 114.
P Published in release R17.1. The following updates are made in this revision:
• Changed the tightening torque of the oil plug located on axis-1 gearbox.

Continued
Q Published in release R17.2. The following updates are made in this revision:
• Information about coupled axes in Updating revolution counters on
page 349.
• Caution about removing metal residues added in sections about SMB
boards.
• Information added into calibration procedure regarding installation of
calibration tool on turning disc, see Overview of the calibration procedure
on the FlexPendant on page 360.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Updated list of applicable standards.
• Article number for the Calibration tool box, Axis Calibration is changed.
• Updated the section Start of robot in cold environments on page 113.
• Updated information regarding replacement of brake release board.
• Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
• Definition of reference calibration clarified.

Product documentation, IRC5

Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed
are valid for IRC5 robot systems.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals

The technical reference manuals describe reference information for robotics
products.
• Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
• Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
• Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
• Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.

Continued
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
The group of manuals includes (among others):
• Operating manual - Emergency safety information
• Operating manual - General safety information
• Operating manual - Getting started, IRC5 and RobotStudio
• Operating manual - IRC5 Integrator's guide
• Operating manual - IRC5 with FlexPendant
• Operating manual - RobotStudio
• Operating manual - Troubleshooting IRC5

How to read the product manual
How to read the product manual

Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.
References to required equipment

The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Action Note/Illustration
3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 21.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.

This page is intentionally left blank
1 Safety
1.1 Introduction to safety information
1 Safety
1.1 Introduction to safety information
Overview
The safety information in this manual is divided into the following categories:
• General safety aspects, important to attend to before performing any service
work on the robot. These are applicable for all service work and are found
in General safety information on page 22.
• Safety signals and symbols shown in the manual and on the robot, warning
for different types of dangers, are found in Safety signals and symbols on
page 44.
• 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 52.

1 Safety
1.2.1 Introduction to general safety information
1.2 General safety information
1.2.1 Introduction to general safety information
Definitions
This section details general safety information for personnel performing installation,
maintenance and repair work.
Sections
The general safety information is divided into the following sections.
Section Examples of content
Safety in the robot system on page 23 This section describes the following:
• safety, service
• limitation of liability
• related information
Protective stop and emergency stop on This section describes protective stop and
page 25 emergency stop.
Safety risks on page 26 This section lists dangers relevant when work-
ing with the product. The dangers are split into
different categories.
• safety risks during installation or service
• risks associated with live electrical parts
Safety actions on page 36 This section describes actions which may be
taken to remedy or avoid dangers.
• fire extinguishing
• safe use of the teach pendant or jogging
device

1 Safety
1.2.2 Safety in the robot system
Validity and responsibility

The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system are
designed and installed correctly. Personnel working with robot must be familiar
with the operation and handling of the industrial robot as described in the applicable
documents, for example:
I
• Operating manual - General safety information
• Product manual
I This manual contains all safety instructions from the product manuals for the robots and the
controllers.
The robot system shall be designed and constructed in such a way as to allow safe
access to all areas where intervention is necessary during operation, adjustment,
and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface
for the connection of external safety devices. An external safety function can
interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
Related information
Type of information Detailed in document Section

Installation of safety devices Product manual for the robot Installation and
commissioning
Changing operating modes Operating manual - IRC5 with FlexPend- Operating modes
ant

1 Safety
Continued
Type of information Detailed in document Section

Restricting the working space Product manual for the robot Installation and
commissioning
Load limits for tools and Product specification for the robot Load diagrams
workpieces
Configuration of safety mod- Application manual - Functional safety
ule (requires Functional safety and SafeMove
options)

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

1 Safety
1.2.4.1 Safety risks during installation and service work on manipulators
1.2.4 Safety risks
Overview
This section includes information on general safety risks to be considered when
performing installation and service work on the manipulator.
These safety instructions have to be read and followed by any person who deals
with the installation and maintenance of the manipulator. Only persons who know
the robot and are trained in the operation and handling of the manipulator are
allowed to maintain the manipulator. Persons who are under the influence of alcohol,
drugs or any other intoxicating substances are not allowed to install, maintain,
repair, or use the manipulator.
The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
General risks during installation and service

• The instructions in the product manual in the chapters Installation and
commissioning, and Repair must always be followed.
• Emergency stop buttons must be positioned in easily accessible places so
that the robot can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install or service/maintain the robot must have the appropriate
training for the equipment in question and in any safety matters associated
with it.
Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the robot and as a result of that affect
the active or passive safety operation. 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 robot system.
Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment
for the robot installation.
Nation/region specific regulations

To prevent injuries and damages during the installation of the robot, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be
complied with.

1 Safety
Continued
Non-voltage related risks

• Make sure that no one else can turn on the power to the controller and robot
while you are working with the system. A good method is to always lock the
main switch on the controller cabinet with a safety lock.
• Safety zones, which must be crossed before admittance, must be set up in
front of the robot's working space. Light beams or sensitive mats are suitable
devices.
• Turntables or the like should be used to keep the operator out of the robot's
working space.
• If the robot is installed at a height, hanging, or other than standing directly
on the floor, there may be additional risks than those for a robot standing
directly on the floor.
• The axes are affected by the force of gravity when the brakes are released.
In addition to the risk of being hit by moving robot parts, there is a risk of
being crushed by the parallel arm (if there is one).
• Energy stored in the robot for the purpose of counterbalancing certain axes
may be released if the robot, or parts thereof, are dismantled.
• When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored heat energy in the controller.
• Never use the robot as a ladder, which means, do not climb on the motors
or other parts during service work. There is a serious risk of slipping because
of the high temperature of the motors and oil spills that can occur on the
robot. There is also a risk of the robot being damaged.
To be observed by the supplier of the complete system

When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Complete robot
Safety risk Description

Hot components!
CAUTION
Motors and gearboxes are HOT after running

the robot! Touching motors and gearboxes
may result in burns!
With a higher environment temperature, more
surfaces on the manipulator will get HOT and
may also result in burns.

1 Safety
Continued

Removed parts may result in collapse of
the robot! WARNING
Take any necessary measures to ensure that

the robot does not collapse as parts are re-
moved. For example, secure the lower arm
according to the repair instruction if removing
the axis-2 motor.
Removed cables to the measurement sys-

tem WARNING
If the internal cables for the measurement

system have been disconnected during repair
or maintenance, then the revolution counters
must be updated.
Cabling

Cable packages are sensitive to mechanical
damage! CAUTION
The cable packages are sensitive to mechan-

ical damage. Handle the cable packages and
the connectors with care in order to avoid
damage.
Gearboxes and motors

Gears may be damaged if excessive force
is used! CAUTION
Whenever parting/mating motor and gearbox,

the gears may be damaged if excessive force
is used!

1 Safety
1.2.4.2 CAUTION - Hot parts may cause burns!
1.2.4.2 CAUTION - Hot parts may cause burns!
Description
During normal operation, many robot parts become hot, especially the drive motors
and gearboxes. Sometimes areas around these parts also become hot. Touching
these may cause burns of various severity.
Because of a higher environment temperature, more surfaces on the robot get hot
and may result in burns.
There is also a risk of fire if flammable materials are put on hot surfaces.
Elimination
The following instructions describe how to avoid the dangers specified above:
Action Information
1 Always use your hand, at some distance, to
feel if heat is radiating from the potentially
hot component before actually touching it.
2 Wait until the potentially hot component has
cooled if it is to be removed or handled in any
other way.
3 Do not put anything on hot metal surfaces,
e.g. paper or plastic.

1 Safety
1.2.4.3 Safety risks related to tools/work pieces
1.2.4.3 Safety risks related to tools/work pieces
Safe handling
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain work pieces in the
event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered robot are prohibited. Without
the consent of ABB it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength could be affected.
CAUTION
Ensure that a gripper is prevented from dropping a work piece, if such is used.

1 Safety
1.2.4.4 Safety risks related to pneumatic/hydraulic systems
1.2.4.4 Safety risks related to pneumatic/hydraulic systems
General
Special safety regulations apply to pneumatic and hydraulic systems.
Note
All components that remain pressurized after separating the machine from the
power supply must be provided with clearly visible drain facilities and a warning
sign that indicates the need for pressure relief before adjustments or performing
any maintenance on the robot system.
Residual energy
• Residual energy can be present in these systems. After shutdown, particular
care must be taken.
• The pressure must be released in the complete pneumatic or hydraulic
systems before starting to repair them.
• Work on hydraulic equipment may only be performed by persons with special
knowledge and experience of hydraulics.
• All pipes, hoses, and connections have to be inspected regularly for leaks
and damage. Damage must be repaired immediately.
• Splashed oil may cause injury or fire.
Safe design
• 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.

1 Safety
1.2.4.5 Safety risks with pressure relief valve
1.2.4.5 Safety risks with pressure relief valve
Introduction
The pressure relief valve must be kept clean and open, for it to be able to function
properly.
Safety risks
The pressure relief valve is a vital part preventing too much air pressure being built
up inside the robot. If too much air pressure has been built up, there is a risk of
personal injury and mechanical damage.

1 Safety
1.2.4.6 Safety risks during operational disturbances
1.2.4.6 Safety risks during operational disturbances
General
• The industrial robot is a flexible tool that can be used in many different
industrial applications.
• All work must be carried out professionally and in accordance with the
applicable safety regulations.
• Care must be taken at all times.
Qualified personnel
Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.
Extraordinary risks
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.

1 Safety
1.2.4.7 Risks associated with live electric parts
Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified
electrician in accordance with electrical regulations.
• Although troubleshooting may, on occasion, need to be carried out while the
power supply is turned on, the robot must be turned off (by setting the main
switch to OFF) when repairing faults, disconnecting electric leads and
disconnecting or connecting units.
• The main supply to the robot must be connected in such a way that it can
be turned off from outside the working space of the robot.
• Make sure that no one else can turn on the power to the controller and robot
while you are working with the system. A good method is to always lock the
main switch on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and robot system during
construction, commissioning, and maintenance is guaranteed if the valid regulations
are followed.
All work must be performed:
• by qualified personnel
• on machine/robot system in deadlock
• in an isolated state, disconnected from power supply, and protected against
reconnection.
Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in
the controller.
• Units such as I/O modules, can be supplied with power from an external
source.
• The main supply/main switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)
• The drive unit (400/700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• 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.

1 Safety
Continued
Voltage related risks, robot

A danger of low voltage is associated with the robot in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max. 230
VAC).
Voltage related risks, tools, material handling devices, etc.

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.

1 Safety
1.2.5.1 Safety fence dimensions
1.2.5 Safety actions
1.2.5.1 Safety fence dimensions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.

1 Safety
1.2.5.2 Fire extinguishing
1.2.5.2 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot or
controller!

1 Safety
1.2.5.3 Emergency release of the robot arm
1.2.5.3 Emergency release of the robot arm
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is detailed in the section:
• Manually releasing the brakes on page 77.
The robot arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.
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!
DANGER
When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways.
Make sure no personnel is near or beneath the robot arm.

1 Safety
1.2.5.4 Brake testing
1.2.5.4 Brake testing
When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.
How to test
The function of the holding brake of each axis motor may be verified as described
below:
1 Run each robot axis to a position where the combined weight of the robot
arm and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the robot does not change position as the motors are switched off, then
the brake function is adequate.

1 Safety
1.2.5.5 Risk of disabling function "Reduced speed 250 mm/s"
1.2.5.5 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".

1 Safety
1.2.5.6 Enabling device and hold-to-run functionality
1.2.5.6 Enabling device and hold-to-run functionality
Three-position enabling device

The three-position enabling device is a manually operated, constant pressure
push-button which, when continuously activated in one position only, allows
potentially hazardous functions but does not initiate them. In any other position,
hazardous functions are stopped safely.
The three-position enabling device is of a specific type where you must press the
push-button only half-way to activate it. In the fully in and fully out positions,
operating the robot is impossible.
Note
The three-position enabling device is a push-button located on the teach pendant

which, when pressed halfway in, switches the system to MOTORS ON. When
the enabling device is released or pushed all the way in, the manipulator switches
to the MOTORS OFF state.
To ensure safe use of the teach pendant, the following must be implemented:
• The enabling device must never be rendered inoperational in any way.
• During programming and testing, the enabling device must be released as
soon as there is no need for the robot to move.
• Anyone entering the working space of the robot must always hold the teach
pendant. This is to prevent anyone else from taking control of the robot
without his/her knowledge.
Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. 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.

1 Safety
1.2.5.7 Work inside the working range of the robot
1.2.5.7 Work inside the working range of the robot
WARNING
If work must be carried out within the work area of the robot, then the following
points must be observed:
• The operating mode selector on the controller must be in the manual mode
position to render the three-position enabling device operational and to block
operation from a computer link or remote control panel.
• The maximum speed of the robot is limited to 250 mm/s when the operating
mode selector is in the position Manual mode with reduced speed. This
should be the normal position when entering the working space.
The position Manual mode with full speed (100%) may only be used by
trained personnel who are aware of the risks that this entails. Manual mode
with full speed (100%) is not available in USA or Canada.
• Pay attention to the rotating axes of the robot. Keep away from axes to not
get entangled with hair or clothing. Also, be aware of any danger that may
be caused by rotating tools or other devices mounted on the robot or inside
the cell.
• Test the motor brake on each axis, according to the section Brake testing
on page 39.
• To prevent anyone else from taking control of the robot, always put a safety
lock on the cell door and bring the three-position enabling device with you
when entering the working space.
WARNING
NEVER, under any circumstances, stay beneath any of the robot's axes! There
is always a risk that the robot will move unexpectedly when robot axes are moved
using the three-position enabling device or during other work inside the working
range of the robot.

1 Safety
1.2.5.8 Signal lamp (optional)
1.2.5.8 Signal lamp (optional)
Description
A signal lamp with a yellow fixed light can be mounted on the robot, as a safety
device.
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.

1 Safety
1.3.1 Safety signals in the manual
1.3 Safety signals and symbols
Introduction to safety signals

This section specifies all dangers that can arise when doing the work described
in the user manuals. Each danger consists of:
• A caption specifying the danger level (DANGER, WARNING, or CAUTION)
and the type of danger.
• A brief description of what will happen if the operator/service personnel do
not eliminate the danger.
• Instruction about how to eliminate danger to simplify doing the work.
Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol Designation Significance
DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
xx0200000022
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height, and so on.
WARNING Warns that an accident may occur if the instructions
are not followed that can lead to serious injury, pos-
sibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
xx0100000002 explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height, etc.
ELECTRICAL Warns for electrical hazards which could result in
SHOCK severe personal injury or death.
xx0200000024
CAUTION Warns that an accident may occur if the instructions

are not followed that can result in injury and/or
damage to the product. It also applies to warnings
of risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping, im-
pact, fall from height, etc. Furthermore, it applies to
xx0100000003
warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.
ELECTROSTATIC Warns for electrostatic hazards which could result
DISCHARGE (ESD) in severe damage to the product.
xx0200000023

1 Safety
Continued
Symbol Designation Significance

NOTE Describes important facts and conditions.
xx0100000004
TIP Describes where to find additional information or

how to do an operation in an easier way.
xx0100000098

1 Safety
1.3.2 Safety symbols on product labels
Introduction to labels
This section describes safety symbols used on labels (stickers) on the product.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The safety and health symbols on the labels on the product must be observed.
Additional safety information given by the system builder or integrator must also
be observed.
Types of labels
Both the manipulator and the controller are marked with several safety and
information labels, containing important information about the product. The
information is useful for all personnel handling the robot, for example during
installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 46.
The information labels can contain information in text (English, German, and
French).
Symbols on safety labels
Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.
xx0900000839

1 Safety
Continued
Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813
Before disassemble, see product manual
xx0900000816
Do not disassemble
Disassembling this part can cause injury.
xx0900000815
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000814
Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808

1 Safety
Continued
Symbol Description
Tip risk when loosening bolts
The robot can tip over if the bolts are not securely fastened.
xx0900000810
xx1500002402
Crush
Risk of crush injuries.
xx0900000817

1 Safety
Continued
Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)
xx0900000818
!
3HAC 4431-1/06
xx1300001087
Moving robot
4 6 The robot can move unexpectedly.
3 5
1
xx0900000819
xx1000001141
2 3
xx1500002616

1 Safety
Continued
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
Chain sling with shortener
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824

1 Safety
Continued
Symbol Description
No mechanical stop
xx1000001144
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.
xx0900000825
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
Do not step
Warns that stepping on these parts can cause damage to the
parts.
xx1400002648

1 Safety
1.4.1 DANGER - Moving robots are potentially lethal!
1.4 Safety related instructions
1.4.1 DANGER - Moving robots are potentially lethal!
Description
Any moving robot is a potentially lethal machine.
When running, the robot may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may
seriously injure any personnel and/or damage any piece of equipment located
within the working range of the robot.
Elimination
Action Note
1 Before attempting to run the robot, make Emergency stop equipment such as gates,
sure all emergency stop equipment is cor- tread mats, light curtains, etc.
rectly installed and connected.
2 Usually the hold-to-run function is active How to use the hold-to-run function is de-
only in manual full speed mode. To in- scribed in section How to use the hold-to-
crease safety it is also possible to activate run function in the Operating manual - IRC5
hold-to-run for manual reduced speed with with FlexPendant.
a system parameter.
The hold-to-run function is used in manual
mode, not in automatic mode.
3 Make sure no personnel are present within
the working range of the robot before
pressing the start button.

1 Safety
1.4.2 DANGER - First test run may cause injury or damage!
1.4.2 DANGER - First test run may cause injury or damage!
Description
Since performing a service activity often requires disassembly of the robot, there
are several safety risks to take into consideration before the first test run.
Elimination
Follow the procedure below when performing the first test run after a service
activity, such as repair, installation, or maintenance.
DANGER
Running the robot without fulfilling the following aspects, may cause severe
damage to the robot.
Action
1 Remove all service tools and foreign objects from the robot and its working area.
2 Verify that the robot is secured to its position, see installation section in the product
manual for the robot.
3 Verify that any safety equipment installed to secure the robot arm position or restrict
the robot arm motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Install all safety equipment properly.
6 Make sure all personnel are standing at a safe distance from the robot, that is out of
its reach behind safety fences, and so on.
7 Pay special attention to the function of the part that previously was serviced.
Collision risks
CAUTION
When programming the movements of the robot, always identify potential collision
risks before the first test run.
Mechanical stops will not always stop the movements of the robot completely.

1 Safety
1.4.3 WARNING - The brake release buttons may be jammed after service work
1.4.3 WARNING - The brake release buttons may be jammed after service work
Description
The brake release unit has push-buttons for the brake release of each axis motor.
When service work is performed inside the SMB recess that includes removal and
refitting of the brake release unit, the brake release buttons may be jammed after
refitting.
DANGER
If the power is turned on while a brake release button is jammed in depressed

position, the affected motor brake is released! This may cause serious personal
injuries and damage to the robot.
Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
1 Make sure the power is turned off.
2 Remove the push-button guard, if necessary.
3 Verify that the push-buttons of the brake release unit are working by pressing them
down, one by one.
Make sure none of the buttons are jammed in the tube.
4 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!

1 Safety
1.4.4 DANGER - Make sure that the main power has been switched off!
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
dangers, do not proceed working before eliminating the danger as detailed below.
Elimination, IRC5 Panel Mounted Controller
Action Note/illustration
1 Switch off the main switch for the controller.
xx0600003255
Elimination, IRC5 Single Cabinet Controller
1 Switch off the main switch on the controller
cabinet.
xx0600002782
A: Main switch

1 Safety
Continued
Elimination, IRC5 Dual Cabinet Controller
1 Switch off the main switch on the Drive
Module.
xx0600002783
K: Main switch, Drive Module

2 Switch off the main switch on the Control A: Main switch, Control Module
Module.

1 Safety
1.4.5 WARNING - The unit is sensitive to ESD!
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Elimination
Action Note
1 Use a wrist strap. Wrist straps must be tested frequently to ensure
that they are not damaged and are operating cor-
rectly.
2 Use an ESD protective floor mat. The mat must be grounded through a current-limit-
ing resistor.
3 Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.
Location of wrist strap button

The location of the wrist strap button is shown in the following illustration.
IRC5
xx1300000856
A Wrist strap button

1 Safety
Continued
Panel Mounted Controller

A A
xx1300001960
A Wrist strap button

1 Safety
1.4.6 WARNING - Safety risks during handling of batteries
1.4.6 WARNING - Safety risks during handling of batteries
Description
Under normal conditions of use, the electrode materials and liquid electrolyte in
the batteries are not exposed to the outside, provided the battery integrity is
maintained and seals remain intact.
There is a risk of exposure only in case of abuse (mechanical, thermal, electrical)
which leads to the activation of safety valves and/or the rupture of the battery
container. Electrolyte leakage, electrode materials reaction with moisture/water or
battery vent/explosion/fire may follow, depending upon the circumstances.
Note
Appropriate disposal regulations must be observed.
Elimination
Action Note
1 Do not short circuit, recharge, puncture, incinerate, crush, Operating temperatures
immerse, force discharge or expose to temperatures above are listed in Pre-install-
the declared operating temperature range of the product. ation procedure on
Risk of fire or explosion. page 64.
2 Use safety glasses when handling the batteries.
3 In the event of leakage, wear rubber gloves and chemical
apron.
4 In the event of fire, use self-contained breathing apparatus.

1 Safety
1.4.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease)
Description
When handling gearbox lubricants, there is a risk of both personal injury and
product damage occurring. The following safety information must be regarded
before performing any work with lubricants in the gearboxes.
Note
When handling oil, grease, or other chemical substances the safety information
of the manufacturer must be observed.
Note
When aggressive media is handled, an appropriate skin protection must be

provided. Gloves and goggles are recommended.
Note
Appropriate disposal regulations must be observed.
Note
Take special care when handling hot lubricants.
Warnings and elimination
Warning Description Elimination/Action

Changing and draining gearbox Make sure that protective gear
oil or grease may require hand- like goggles and gloves are al-
ling hot lubricant heated up to ways worn during this activity.
90 °C.
xx0100000002
Hot oil or grease

When working with gearbox lub- Make sure that protective gear
ricant there is a risk of an allergic like goggles and gloves are al-
reaction. ways worn.
xx0100000002
Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. 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

1 Safety
Continued
Warning Description Elimination/Action

Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease!
turn may: After filling, verify that the level
xx0100000002 • damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Al-
ways use the type of oil specified
xx0100000002
by the manufacturer!
Do not mix types of oil
Warm oil drains quicker than When changing gearbox oil, first
cold oil. run the robot for a time to heat
up the oil.
xx0100000098
Heat up the oil

The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
xx0100000004
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume
When draining the oil make sure
that as much oil as possible is
drained from the gearbox. The
reason for this is to drain as
much oil sludge and metal chips
as possible from the gearbox.
xx0100000003
The magnetic oil plugs will take
Contaminated oil in care of any remaining metal
gear boxes chips.

2 Installation and commissioning
2.1 Introduction

2.1 Introduction
General
This chapter contains assembly instructions and information for installing the IRB
4600 at the working site.
More detailed technical data can be found in the Product specification for the IRB
4600, such as:
• Load diagram
• Permitted extra loads (equipment), if any
• Location of extra loads (equipment), if any.
Safety information
Before any installation work is commenced, it is extremely important that all safety
information is observed!
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 21 before performing any installation
work.
Note
If the IRB 4600 is connected to power, always make sure that the robot is
connected to protective earth before starting any installation work!
For more information see:
• Product manual - IRC5

2.2.1 Pre-installation procedure
2.2 Unpacking
Introduction
This section is intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.
Prerequisites for installation personnel

Installation personnel working with an ABB product 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.
Checking the pre-requisites for installation
Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.
Note
Stop unpacking and contact ABB if transport damages are found.
4 Clean the unit with a lint-free cloth, if necessary.

5 Make sure that the lifting accessory used (if required) is suitable to handle the weight
of the robot as specified in: Weight, robot on page 64
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 66
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 67
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 65
• Protection classes, robot on page 67
• Requirements, foundation on page 66
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 72
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 73
11 Install required equipment, if any.
• Installation of signal lamp (option) on page 96
Weight, robot
The table shows the weight of the robot.
Robot model Weight
IRB 4600 440 kg

Continued
Note
The weight does not include tools and other equipment fitted on the robot!
Loads on foundation, robot

The illustration shows the directions of the robots stress forces.
The directions are valid for all floor mounted, suspended and inverted robots.
Txy
Fz
Fxy
Tz
xx1100000521
Fxy Force in any direction in the XY plane

Fz Force in the Z plane
Txy Bending torque in any direction in the XY plane
Tz Bending torque in the Z plane
The table shows the various forces and torques working on the robot during different
kinds of operation.
Note
These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
Floor mounted
Force Endurance load (in operation) Max. load (emergency stop)

Force xy ±3940 N ±7790 N
Force z 4350 ±2460 N 4350 ±6360 N
Torque xy ±6850 Nm ±14090 Nm
Torque z ±1610 Nm ±2960 Nm

Continued
Suspended
Force Endurance load (in operation) Max. load (emergency stop)

Force xy ±3940N ±7790 N
Force z -4350 ±2460N -4350 ±6360 N
Torque xy ±6850 Nm ±14090 Nm
Torque z ±1610 Nm ±2960 Nm
Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.5 mm Flat foundations give better repeatability of the
surface resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
In order to compensate for an uneven surface,
the robot can be recalibrated during installation.
If resolver/encoder calibration is changed this
will influence the absolute accuracy.
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 The value is recommended for optimal perform-
frequency ance.
Note Due to foundation stiffness, consider robot mass
including equipment. i
It may affect the For information about compensating for founda-
manipulator life- tion flexibility, see Application manual - Control-
time to have a ler software IRC5, section Motion Process Mode.
lower resonance
frequency than
recommended.
i The minimum resonance frequency given should be interpreted as the frequency of the robot
mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e.,
the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should
not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent
mass of the floor is very high, it will not affect robot movement, even if the frequency is well below
the stated 25 Hz. The robot should be mounted as rigid as possibly to the floor.
Disturbances from other machinery will affect the robot and the tool accuracy. The robot has
resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified,
although somewhat damped by the servo control. This might be a problem, depending on the
requirements from the applications. If this is a problem, the robot needs to be isolated from the
environment.
Storage conditions, robot

The table shows the allowed storage conditions for the robot:
Parameter Value
Minimum ambient temperature -25° C
Maximum ambient temperature +55° C
Maximum ambient temperature (less than 24 hrs) +70° C

Continued
Parameter Value
Maximum ambient humidity 95% at constant temperature
(gaseous only)
Operating conditions, robot

The table shows the allowed operating conditions for the robot:
Parameter Value
Minimum ambient temperature +5°C
Maximum ambient temperature +45°C
Maximum ambient humidity 95% at constant temperature
(gaseous only)
Protection classes, robot

The table shows the available protection types of the robot, with the corresponding
protection class.
Protection type Protection class
Manipulator, protection type Standard IP 67
Manipulator, protection type Foundry Plus IP 67

2.2.2 Working range and type of motion
Working range
The figures show the working ranges of the robot variants mounted in different
ways.
The extreme positions of the robot arm are specified at the wrist center (dimensions
in mm).
Working range, floor mounted

The illustration shows the unrestricted working range when the robot is floor
mounted.
xx0800000267
Variant Pos. A Pos. B Pos. C Pos. D Pos. E Pos. F

IRB 4600 - 60/2.05 2371 mm 1260 mm 1028 mm 593 mm 1701 mm 2051 mm

Continued
Working range, suspended mounted

The illustration shows the unrestricted working range when the robot is suspended
mounted.
xx0900000055
Variant Pos. A Pos. B Pos. C Pos. D Pos. E Pos. F


Continued
Turning radius
The turning radius of the robot that is floor or suspended mounted is shown in the
figure.
+180°
A
B
-180°
xx0800000268
Variant Pos. A Pos. B

IRB 4600 - 60/2.05 R2051 R593
IRB 4600 - 45/2.05 R2051 R593
IRB 4600 - 40/2.55 R2552 R680
IRB 4600 - 20/2.50 R2513 R665
Robot motion, IRB 4600-60/2.05, -45/2.05, -40/2.55

The table specifies the types and ranges of motion in every axes.
Location of motion Type of motion Range of movement
Axis 1 Rotation motion ±180°
Axis 2 Arm motion +150° / -90°
Axis 4 Wrist motion ±400°
Axis 5 Bend motion +120° / -125°
Axis 6 Turn motion ±400°

Continued
Robot motion, IRB 4600-20/2.50

The table specifies the types and ranges of motion in every axes.
Location of motion Type of motion Range of movement
Axis 1 Rotation motion ±180°
Axis 4 Wrist motion ±400°
Axis 5 Bend motion ±120°
Axis 6 Turn motion ±400°

2.2.3 Risk of tipping/stability
2.2.3 Risk of tipping/stability
Risk of tipping
If the robot is not fastened to the foundation while moving the arm, the robot is not
stable in the whole working area. Moving the arm will displace the center of gravity,
which may cause the robot to tip over.
The shipping position is the most stable position.
Do not change the robot position before securing it to the foundation!
Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.
The position of the calibration mark (A) in the figure is approximate and is used as
aiming aid.
0°
45°
A
15
°
xx0800000263
WARNING
The robot is likely to be mechanically unstable if not secured to the foundation.

2.3.1 Lifting robot with roundslings
2.3 On-site installation
Introduction
When lifting the robot use roundslings and an overhead crane.
How to lift suspended mounted robot is described in the lifting instruction delivered
with the turning tool art. no. 3HAC034766-001. See Lifting and turning a suspended
mounted robot on page 76.
Required equipment
Equipment Note
Overhead crane Lifting capacity 1 000 kg (Max load at 90°)
Roundslings (2 pcs) • Lifting capacity/roundsling: 1 000 kg
• Length: 2 m
Lifting
Attach the roundslings as shown in the figure.
xx0800000262
A Roundsling put folded in U-shape through the lifting lug

B Roundsling put folded in U-shape around gearbox axis 3
C Lifting lug

Continued
Lifting instructions
Use this procedure to lift the robot in a safe way.
Action Note
1
CAUTION
The IRB 4600 robot weighs 440 kg.

All lifting accessories used must be sized ac-
cordingly!
2
CAUTION
Attempting to lift the robot in any other posi-

tion than that recommended may result in the
robot tipping over and causing severe damage
or injury!
3
WARNING
Personnel must not, under any circumstances,

be present under the suspended load!
4 Move the robot to its most stable position. Detailed in section:

• Risk of tipping/stability on
page 72
5
DANGER
Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.
6 Attach roundsling A to the lifting lug on the See the figure in:
frame, and put folded in a U-shape on either • Lifting on page 73
side of the upper arm.
7 Attach roundsling B at axis 3 gearbox by run- See the figure in:
ning it folded in a U-shape around the gear- • Lifting on page 73
box.
8 Make sure the roundslings do not rub against
any sharp edges.

Continued
Action Note
9 When the robot is lifted the roundslings will
adjust themselves.
CAUTION
When lifting, the robot will tilt slightly back-

wards! Be careful not to damage the connec-
tion box at the base of the robot!
xx0800000291
• A: Area where the connection

box can be damaged while lifting.
10 Lift the robot with an overhead crane. Lifting capacity:
• See Required equipment on
page 73

2.3.2 Lifting and turning a suspended mounted robot
2.3.2 Lifting and turning a suspended mounted robot
Introduction
How to lift and turn the robot to a suspended position using the turning accessory
is described in the lifting instruction delivered with the turning accessory. Article
numbers for the accessory and the instruction is specified in Special tools on
page 386. Any additional equipment required is specified in the instruction for the
lifting accessory. Contact ABB for more information.
How to lift and turn the robot into position for tilted position: Contact ABB for more
information!
Illustration
xx1500002116

2.3.3 Manually releasing the brakes
General
The section below describes how to release the holding brakes of each axis' motor.
This can be done in one of three ways:
• using the push-button when the robot is connected to the controller.
• using the push-button on the robot with an external power supply.
• using an external voltage supply directly on the respective brake.
DANGER
When releasing the holding brakes with push-buttons, the robot must be properly
attached!
DANGER
When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways!
Make sure no personnel is near or beneath the robot arm!
Using the push-button when the robot is connected to the controller

This procedure details how to release the holding brakes with push-buttons, when
the robot is connected to the controller.
Action Note
1 The internal brake release unit is located
at the base of the robot.
xx0800000272
2 The brake release unit is equipped with

six buttons for controlling the axes brakes.
The buttons are numbered according to
the numbers of the axes.
3 Release the holding brake on a particular
axis by pressing the corresponding button
on the push-button unit and keeping it
depressed.
4 The brake will function again as soon as
the button is released.

Continued
Using the push-button on the robot with an external power supply

This procedure details how to release the holding brakes with the push-buttons,
when the robot is not connected to the controller.
Action Note
1 Connect an external 24VDC power supply to
the connector R1.MP on the robot base.
Note
Be careful not to interchange the 24V and 0V

pins!
If they are mixed up, damage can be caused
to the brake release unit and the system
board!
WARNING
Incorrect connections can cause all brakes

to be released simultaneously!
xx0800000269
Connect to connector R1.MP:

• 0V to pin 12
• +24V to pin 11
2 Release the holding brake on a particular The brake release unit is equipped with
axis by pressing the corresponding button six buttons for controlling the axes
on the push-button unit and keeping it de- brakes. The buttons are numbered accord-
pressed. ing to the numbers of the axes.
See the previous figure.
3 The brake will function again as soon as the
button is released.

Continued
Using an external voltage supply directly on the respective brake

This procedure details how to release the holding brake of a specific axis by
supplying external voltage directly on the brake.
Action Note
1 Every axis has a holding brake built into the Make the connection to the current motor
axis motor. This holding brake may be re- according to the Circuit Diagram.
leased by connecting 24VDC power supply See chapter Circuit diagram on page 393.
directly to one of the connectors in the motor.
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!
2 Connect an external 24 VDC power supply Axes 1, 2 and 3:

to the motor, according to the figures. Pos 2: +24 V
Note
Be careful not to interchange the 24V and 0V

pins!
If they are mixed up, damage can be caused Pos 5: 0 V
to the intergrated quenching circuits.
WARNING
Incorrect connections can cause all brakes

to be released simultaneously! xx1400001984

2.3.4 Orienting and securing the robot
Introduction
This section describes how to orient and secure the robot to the foundation or base
plate in order to run the robot safely. The requirements made on the foundation
are shown in sections Loads on foundation, robot on page 65 and Requirements,
foundation on page 66.
Hole configuration, base

The illustration shows the hole configuration used when securing the robot.
xx0800000271
C Hole for guide bushing

D Rear bolt holes

Continued
Dimension, mounting surface and guide bushing

The figure shows the dimension of the mounting surface and guide bushings.
E F
Ø60
Ø0.5 AB
C C (3 2.5 25
X1
20 2x 1x45º
Ø 35 -0.025 f7
º) (A)
-0.050
Ø22
1.6
Ø 500
A B B
A
0.5 (C)
Ø35 +0.024 J8
1
-0.015
216.5 2x Ø 90 R
B
(433±0.5)
G 433 ±0.5
G (D)
Ø35 +0.024 J8
-0.015
A (37)
1.6
1x45º
10 10
20 min 20 min 30 min
M16 M16 M16

A-A B-B C-C
xx1700001492
(C) 3x common zone

E Position of the front of the robot
F M16 (3 pcs)
G Guide bushings (2 pcs)
Specification, attachment screws

The table specifies the type of securing screws and washers to be used to secure
the robot to the foundation or base plate.
Securing parts/Facts Dimension Note
Securing screws, oiled M16 x 60 (installation directly 6 pcs
on foundation) 200 Nm
M16 x 70/80 (installation on
foundation or base plate, us-
ing guide bushings)
Quality 8.8
Washers 17 x 30 x 3 6 pcs

Continued
Securing parts/Facts Dimension Note

Guide bushings Article number: 21510024-
169, 2 pcs.
Added to the rear bolt holes,
to allow the same robot to be
re-mounted without program
adjustments.
xx1200000885
Level surface requirements
xx0300000251
Orienting and securing the robot

Use this procedure to orient and secure the robot.
Action Note
1 Make sure the installation site for the robot
conforms to the specifications in section Pre-
installation procedure on page 64.
2 Prepare the installation site with attachment Hole configuration of the base is shown
holes. in the figure in:
• Hole configuration, base on
page 80
3
CAUTION

All lifting accessories used must be sized
accordingly!
4
CAUTION
When the robot is put down after being lifted

or transported, there is a risk of it tipping, if
not properly secured.
5 Lift the robot to its installation site. How to lift the robot is described in sec-
tion:
• Lifting robot with roundslings on
page 73
6 Fit two guide bushings to the rear bolts in the
base.
7 Guide the robot gently, using the attachment Make sure the robot base is correctly fit-
screws while lowering it into its mounting ted onto the guide sleeves.
position.

Continued
Action Note
8 Fit the securing screws and washers in the
attachment holes of the base.
9 Tighten the bolts in a criss-cross pattern to
ensure that the base is not distorted.
Securing robot on a mounting plate

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 65.

2.3.5 Setting the system parameters for a suspended or tilted robot
General
The robot is configured for mounting parallel to the floor, without tilting, on delivery.
The method for mounting the robot in a suspended (upside down) or tilted position
is basically the same as for floor mounting, but the system parameters that describe
the mounting angle (how the robot is oriented relative to the gravity) must be
redefined.
Note
With suspended installation, make sure that the gantry or corresponding structure
is rigid enough to prevent unacceptable vibrations and deflections, so that
optimum performance can be achieved.
Note
The allowed mounting positions are described in the product specification for
the robot. The requirements on the foundation are described in Requirements,
foundation on page 66.
System parameters
Note
The mounting angle must be configured correctly in the system parameters so

that the robot system can control the movements in the best possible way. An
incorrect definition of the mounting angle will result in:
• Overloading the mechanical structure.
• Lower path performance and path accuracy.
• Some functions will not work properly, for example Load Identification and
Collision detection.
Gravity Beta
If the robot is mounted upside down or tilted (rotated around the y-axis), then the
robot base frame and the system parameter Gravity Beta must be redefined. Gravity
Beta should then be π (±3.141593) if the robot is mounted upside down (suspended).
The Gravity Beta is a positive rotation direction around the y-axis in the base
coordinate system. The value is set in radians.

Continued
Gravity Alpha
The Gravity Alpha is a positive rotation direction around the x-axis in the base
coordinate system. The value is set in radians.
Note
The system parameter Gravity Alpha is not supported for all robot types. It is not
supported for IRB 140, IRB 1410, IRB 1600ID, IRB 2400, IRB 4400, IRB 6400R,
IRB 6400 (except for IRB 6400 200/2.5 and IRB 6400 200/2.8), IRB 6600, IRB
6650, IRB 6650S and IRB 7600 (except for IRB 7600 325/3.1).
If the robot does not support Gravity Alpha, then use Gravity Beta along with the
recalibration of axis 1 to define the rotation of the robot around the x-axis.
Note
The parameter is supported for all robots on track when the system parameter
7 axes high performance motion is set, see Technical reference manual - System
parameters.
Gamma Rotation
Gamma Rotation defines the orientation of the robot foot on the travel carriage
(track motion).
Mounting angles and values

The parameter Gravity Beta (or Gravity Alpha) specifies the mounting angle of the
robot in radians. It is calculated in the following way.
Gravity Beta = A° x 3.141593/180 = B radians, where A is the mounting
angle in degrees and B is the mounting angle in radians.
Example of position Mounting angle (A°) Gravity Beta

Floor mounted 0° 0.000000 (Default)
Tilted mounting 15° 0.261799
Suspended mounting 180° 3.141593

Continued
Examples of mounting angles tilted around the Y axis (Gravity Beta)
xx1700000267
A Floor mounted
B Tilted mounting, mounting angle 15°.
C Suspended mounting, mounting angle 180°.

Continued
Examples of mounting angles tilted around the X axis (Gravity Alpha)
xx1700000268
- Tilted mounting, mounting angle 15°.
Note
For suspended robots (180°), it is recommended to use Gravity Beta instead of

Gravity Alpha.
Defining the parameter in the IRC5 software

The value of the system parameters that define the mounting angle must be
redefined when changing the mounting angle of the robot. The parameters belong
to the type Robot, in the topic Motion.
How to calculate a new value is detailed in Mounting angles and values on page 85.
The system parameters are described in Technical reference manual - System
parameters.
The system parameters are redefined in the Configuration Editor, in RobotStudio
or on the FlexPendant.

2.3.6 Fitting equipment on robot
Introduction
The robot features mounting holes for additional equipment.
Access to any of the following mounting holes may be obstructed by any additional
cabling, equipment, etc., fitted by the robot user. Make sure the required mounting
holes are accessible when planning the robot cell.
Note
All equipment and cables used on the robot, must be designed and fitted not to
damage the robot and/or its parts.
Note
Never drill a hole in the robot without first consulting ABB!
Fitting equipment on robot - Load areas

The shaded area indicates the permitted positions (center of gravity) for any extra
equipment fitted in the holes intended for this purpose.
xx0800000275
Variant Max load A Max load B Max load C Max load A+C Max load D
IRB 4600-60/2.05 15 kg 5 kg i 15 kg 15 kg 35 kg
IRB 4600-45/2.05 15 kg 5 kg ii 15 kg 15 kg 35 kg

Continued
Variant Max load A Max load B Max load C Max load A+C Max load D
IRB 4600-40/2.55 15 kg 5 kg iii 15 kg 15 kg 35 kg
IRB 4600-20/2.50 10 kg 1 kg 10 kg 10 kg 35 kg
i Payload + B = Max 60 kg
ii Payload + B = Max 45 kg
iii Payload + B = Max 40 kg
Note
Maximum loads must never be exceeded!
Fitting equipment on base and frame

The illustrations show the fitting holes available for fitting extra equipment on the
base and frame of the robot.
xx0800000276
A Attachment holes on base

B Center axis 2

Continued
Fitting equipment on lower and upper arm

The illustrations show the fitting holes available for fitting extra equipment on the
lower and upper arm of the robot.
216 (2x M8 16) 90(3x M8 16)
A
130
2x M8 16 110 65 3x M8 16
0,3 0,3
190 80
80
190
C
L
B
xx0800000280
A Center axis 4
B Center axis 3

Continued
xx0800000279
Variant A (mm) B (mm) C (mm) D (mm) E (mm) F (mm) G H (mm) J (mm)

(mm)
60/2.05 1727 900 See 1276 960 135 20 See 237
note i note i
45/2.05 1727 900 See 1276 960 135 20 See 237
note i note i
40/2.55 1922 1095 315 1586 1270 135 20 28 237
20/2.50 1922 1095 315 1496.5 1230.5 85 20 28 237
i Position H and measurement C is only applicable to IRB 4600 - 40/2.55 and IRB 4600 - 20/2.50.
Position H and measurement C is only applicable to IRB 4600 - 40/2.55 and IRB 4600 - 20/2.50.
Variant Attachment screws

60/2.05 4x M8, through

Continued
Fitting equipment on wrist and mounting flange

Extra equipment on wrist, robot versions IRB 4600 -60/2.05, -45/2.05 and -40/2.55
The illustration shows the fitting holes available for fitting extra equipment on the
wrist of the robot.
xx0800000277
Note
Do not remove screws indicated in the illustration below!
xx0800000281
A Screws not to be removed! Do not use these holes for fitting equipment on the
wrist!
B Screw hole intended for swivel fitting.

Continued
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.
There are two versions of the mounting flange, differences are shown in the figures.
The mounting flange has through holes with a thread all the way through.
xx0800000282
The mounting flange has through holes with a thread only part way through the hole.
+0,036
8 H9 0 8 min.
E
0,05 C D
F
30°
SECTION F-F
°
60
5x
63 H8
6x M10 17 1
0,3 C D E
R 50
F 9 min.
10
xx1600000626
Note
Use attachment screws M10, quality 12.9 and 15 mm used thread length.

Continued
Extra equipment on wrist and mounting flange, robot version IRB 4600 -20/2.50
The illustration shows the fitting holes available for fitting extra equipment on the
wrist of the robot version IRB 4600 -20/2.50.
The illustration also shows the mechanical interface for the mounting flange of the
robot version IRB 4600 -20/2.50.
110
6 H7 8
12,5
D
0,05 B C
30°
25
P
50
P-P
60°
2x M6 12 10
C
B
79 (2x M6)
6x M6
63 h8
31,5H8
0,3 B C D
P
7
A = R98
xx0800000278
A Smallest circumscribed radius axis 4
Note
Use attachment screws M6, quality 12.9 and 10 mm used thread length.

2.3.7 Loads fitted to the robot, stopping time and braking distances
2.3.7 Loads fitted to the robot, stopping time and braking distances
General
Any loads mounted on the robot must be defined correctly and carefully (with
regard to the position of center of gravity and mass moments of inertia) in order
to avoid jolting movements and overloading motors, gears and structure.
CAUTION
Incorrectly defined loads may result in operational stops or major damage to the
robot.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must also be defined in the software as
detailed in:
Stopping time and braking distances

The performance of the motor brake depends on if there are any loads attached
to the robot. For more information, see product specification for the robot.

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.

2.4.1 Axes with restricted working range
2.4 Restricting the working range
2.4.1 Axes with restricted working range
General
When installing the robot, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space
should be limited.
The working range of the following axes may be restricted:
• Axis 1, hardware (mechanical stop) and software
• Axis 2, software
• Axis 3, software.
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.
WARNING
Remove the mechancial stop bracket if the robots full working range is from a
mechanical stop to another mechanical stop. Otherwise the mechanical stop pin
will be worn out.
xx1500000253

2.4.2 Mechanically restricting the working range of axis 1
Mechanically restricting the working range

The information in this section is valid both for the floor and the suspended mounted
robot.
The working range of axis 1 is limited by fixed mechanical stops. The working
range can be reduced further by adding movable mechanical stops.
The mechanical turning range can be limited in steps of 22.5° from the
synchronization position, between values defined in the table. The values differ
depending on which design of the gearbox (and base) the robot is equipped with.
Design of gearbox i Limitation in mechanical turning range, calculated
from synchronization position
Type C ±126° to ±13.5° in steps of 22.5°
Other design than Type C ±129° to ±16.5° in steps of 22.5°
i Description of the different designs of gearboxes is found in Type C of IRB 4600 on page 375.
Note
The software working range limitations must be adjusted to correspond to the

changes in the mechanical limitations of the working range. The system
parameters that must be changed (Upper joint bound and Lower joint bound)
are described in Technical reference manual - System parameters.
Required equipment
Equipment, etc. Art. no. Note

Mechanical stop, axis 1 See Spare part Includes two additional stop lugs, attachment
lists on page 391. screws, washers and instruction
Attachment screw See Spare part 2 pcs/stop lug
lists on page 391. Hex socket head cap screw M12x40, quality
8.8-A3F
Washer See Spare part 2 pcs/lug
lists on page 391. 13x24x2.5
Standard toolkit Content is defined in section Standard tools

on page 385.
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.

Continued
Additional stops
The additional stops are fitted as shown in the figure.
D, E
xx0800000273
A Movable mechanical stop. Limited to -126° (Type C) or -129° (other design than
Type C).
B Movable mechanical stop. Limited to +13.5° (Type C) or +16.5° (other design
than Type C).
C Movable mechanical stop. Limited to -13.5° (Type C) or -16.5° (other design
than Type C).
D Attachment screws
E Washers
Fitting, mechanical stop axis 1

How to fit the additional mechanical stop to the base is described in the procedure.
Mounting instructions are also supplied with the kit.
Action Note
1 Determine the position of the stop lugs. See the figure Additional stops on
page 99 for guidance.
2 Fit the stop lugs firmly with attachment Specified in Required equipment on
screws and washers according to the figure page 98.
Additional stops on page 99. Tightening torque: 82 Nm

Continued
Preparing the robot for working range ±180º

This procedure describes how to prepare the robot for working range ±180º.
Action Note
1
DANGER
Turn off all:

to the robot, before entering the robot work-
ing area.
2 Remove the two screws holding the mechan-

ical stop and the bracket.
xx1100000091
A Attachment screw
B Bracket, stop axis 1
3 Remove the bracket.
4 Refit the attachment screws.

2.5.1 Installation of cooling fan for motors (option)
2.5 Installing options
General
A cooling fan can be installed on motor axis 1 and/or axis 2!
Location of cooling fans

The fans are installed on the motors, axes 1 or 2, as shown in the figure below.
xx0900000135
A Fan, motor axis 2

B Fan, motor axis 1
C Protection cover

Continued
Cooling fan
The details of the cooling fan are shown in the figure below.
xx0500002158
A Fanbox (motor axis 2)

B Attachment screws, fanbox plates (9 pcs)
C Groove in the connector
D Tightening screws, fanbox (3 pcs)

Continued
xx0900000137
A Fanbox (motor axis 1)

B Groove in the connector
C Back plate
D Part of the fanbox that can be removed, if needed.
Required equipment
Equipment Article number Note

Cooling fan axis 1, set - For Spare part no. see chapter Spare
parts, section:
• Spare part lists on page 391
Cooling fan axis 2, set - For Spare part no. see chapter Spare
parts, section:
Locking liquid - Loctite 243. Used for the three tightening
screws.
Standard toolkit - Content is defined in section Standard
tools on page 385.
Circuit diagram - See chapter Circuit diagram on page 393.
Other tools and procedures These procedures include references to
may be required. See refer- the tools required.
tions below.

Continued
Installation, fan on motor axis 1

Use this procedure to install the cooling fan on motor axis 1.
Action Note
1
DANGER
Turn off all:

• electric power supply to the robot
• hydraulic pressure supply to the robot
• air pressure supply to the robot
Before entering the robot working area.
2 Remove the back plate of the fanbox. See the figure in:
• Cooling fan on page 102
3 Place the fanbox around motor axis 1. See the figure in:
4 Refit the back plate of the fanbox.
5 See the figure in:
Tip • Cooling fan on page 102
If there is a lack of space between motor and

robot, it is possible to remove part of the fanbox.
6 Push the fanbox in line with the connection box. Align the upper part of the fan with the
lower part of the connection box.
A B C
xx1000000124
Parts:
• A: Connection box
• B: Position where the fan shall
be aligned with connection box
• C: Fan
7 Fit the fanbox with two attachment screws
M6x25.

Continued
Action Note
8 Connect the fan connector to motor and fan.
xx0900000405
Parts:
• A: Connector, signal
• B: Connector, power
• C: Fan cable
• D: Connector, fan
• E: Cable gland
• F: Motor cover, with fan cable
9 After fitting the motor cover, fit the protection A
cover using two attachment screws for the
motor cover.
xx0900000406
Parts:
• A: Protection cover
• B: Fan
10 Secure the fan cable to the protection cover
with a cable strap.

Continued
Installation, fan on motor axis 2

Use this procedure to install the cooling fan on motor axis 2.
Action Note
1
DANGER
Turn off all:

• electric power supply to the robot
• hydraulic pressure supply to the robot
• air pressure supply to the robot
Before entering the robot working area.
2 Remove the back plate of the fanbox. See the figure in:
3 Place the fanbox around motor axis 1.
4 Refit the back plate of the fanbox. See the figure in:
5 Fit the fanbox with two attachment screws
M6x30.
6 Connect the fan connector to motor and fan.
xx0900000405
Parts:
• A: Connector, signal
• B: Connector, power
• C: Fan cable
• D: Connector, fan
• E: Cable gland
• F: Motor cover, with fan cable

Continued
Action Note
7 After fitting the motor cover, fit the protection A
cover using two attachment screws for the mo-
tor cover.
xx0900000406
Parts:
• A: Protection cover
• B: Fan

2.5.2 Installation of Foundry Plus Cable guard (option no. 908-1)
2.5.2 Installation of Foundry Plus Cable guard (option no. 908-1)
Introduction
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

2.5.3 Installing an expansion container
Note
This section is not applicable to type C. Expansion container is not needed on

this type.
Introduction to the expansion container

The expansion container is needed on suspended robots to make sure that the
amount of oil in gearbox axis 1 covers all important parts. Robots ordered as
suspended robots have the expansion container installed on delivery.
Expansion container
xx1000000318
A Cover
B Attachment screw M6x16, quality 8.8-A2F (5 pcs)
C Oil expansion container with cover
D Base
E O-ring D220x5
F Attachment screw M5x20, quality 8.8-A2F and washer (2+2 pcs)
G O-ring D1=9.5 D2=1.6
H Oil plug (to be removed)

Continued
Required equipment
Equipment Note
Expansion container Kit including oil.
Lifting accessory 3HAC034766-001
Lifting instruction Included with the lifting accessory.
Grease -
O-ring for base cover Replace if damaged.
Installing an expansion container

Use this procedure to install the expansion container.
Action Information
1 Lift the robot using the lifting accessory and See Lifting and turning a suspended
place it in suspended position with the base mounted robot on page 76.
free for installation work.
2 Remove the cover and the o-ring from the
base.
3 Remove the two existing attachment screws.
xx1500001958
The screws must be replaced with longer

screws.
4 Remove the oil plug from the base.
5 Apply some grease on the small o-ring and
place it in the recess on the expansion con-
tainer.
6 Fit a plastic plug in the oil drain hole.
xx1500001956

Continued
Action Information
7 Fill oil in expansion container, and press
down the VK-cover. Secure with three screws
and washers.
xx1500001957
8 Place the expansion container in the base

and place it so the drain holes match.
9 Secure the expansion container with the at-
tachment screws and washers.
xx1500001959
Tightening torque 6 Nm.

10 Check the o-ring used on the cover. Replace
it if damaged.
11 Refit the cover on the base with its attach-
ment screws.
12 Turn the robot so it is not suspended.
13 Turn the robot to suspended position.
14 Inspect the oil level. See procedure for suspended robot, In-
specting oil level, axis 1 gearbox on
page 126.

2.6.1 Start of robot in hot environments
2.6 Robot in hot environments
2.6.1 Start of robot in hot environments
Introduction
This procedure describes how to start the robot in a hot environment. This
procedure must be performed the first time the robot is started in a hot environment
or if it has not been used for some time in a hot environment.
There is a possibility that some overpressure has been built up in the system. This
overpressure must be released before starting up the robot.
Releasing overpressure in gearboxes

Use this procedure before the start of the robot in a hot environment to release
potential overpressure being built up in gearboxes.
Action Note
1
DANGER
Turn off all:

ing area.
2
CAUTION
Before approaching the potentially hot robot

component, observe the safety information
in section CAUTION - Hot parts may cause
burns! on page 29.
3
Note
Before opening the oil plug, make certain that

the oil plug is above the oil level. Place the
robot accordingly.
4 Open oil plug filling very carefully!

Tip
Note
Hold a cloth or some paper over the oil
Open the oil plug just enough for the overpres- plug while opening it to prevent surplus
sure to be released. oil causing burns or other injuries.
5 Let the overpressure leave the gearbox.

6 Refit the oil plug.
7 Continue releasing the overpressure on all
gearboxes.

2.7.1 Start of robot in cold environments
2.7 Robot in cold environments
2.7.1 Start of robot in cold environments
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
Problems with starting the robot

Event message from Motion supervision
Use this procedure if an event message indicates a problem with Motion supervision
at start-up.
Action Note
1 Turn off motion supervision.
2 Start the robot.
3 When the robot has reached normal working temper-
ature, the motion supervision can be turned on
again.
Robot stopping with other event message

Use this procedure if the robot is not starting.
Action Note
1 Start the robot with its normal program but The speed can be regulated with the
with reduced speed. RAPID instruction VelSet.
Adjusting the speed and acceleration during warm-up

Depending on how cold the environment is and what program is being used, the
speed might need to be ramped up until reached maximum. The table shows
examples of how to adjust the speed:
Work cycles AccSet Speed/velocity
3 Work cycles 20, 20 v100 (100 mm/s)
5 Work cycles 40, 40 v400 (400 mm/s)
5 Work cycles 60, 60 v600 (600 mm/s)
5 Work cycles 100, 100 v1000 (1000 mm/s)
More than 5 Work cycles 100, 100 Max.
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.

2.8.1 Robot cabling and connection points
2.8 Electrical connections
Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.
Main cable categories

All cables between the robot and controller are divided into the following categories:
Cable category Description
Robot cables Handles power supply to and control of the robot's motors
as well as feedback from the serial measurement board.
Specified in the table Robot cables on page 114.
Fan cables (option) Handles supply to and feedback from any cooling fan on
the robot.
Specified in the table Fan cables (option) on page 116.
Customer cables (option) Handles communication with equipment fitted on the robot
by the customer, low voltage signals and high voltage power
supply + protective ground.
The customer cables also handle databus communication.
See the product manual for the controller, see document
number in References on page 10.
External axes cables (option) Handles power supply to and control of the external axes'
motors as well as feedback from the servo system.
See the Application manual - Additional axes and stand
alone controller (M2004), see document number in Refer-
ences on page 10.
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet
to the robot motors.
Robot cable, signals Transfers resolver data from XS2 R1.SMB
and power supply to the serial
measurement board.
Robot cable, power
Cable Art. no.

Robot cable, power: 7 m 3HAC026787-001

Continued
Robot cable, signals
Cable Art. no.

Robot cable signal, shielded: 7 m 3HAC2493-1
Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.
A
B
xx1600002016
A Diameter
B Diameter x10
Grounding and bonding point on manipulator

There is a grounding/bonding point on the manipulator base. The grounding/bonding
point is used for potential equalizing between control cabinet, manipulator and any
peripheral devices.
xx1600001004

Continued
Fan cables (option)

These cables are not included in the standard delivery, but are included in the
delivery if the fan option is ordered. 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 101.

2.8.2 Customer connection on robot
Location of customer connection

For the connection of extra equipment to the robot, cables and air hose are
integrated into the robot´s cabling, and there is one UTOW71210SH06 and one
UTOW71626SH06 connector on the front part of the upper arm.
The customer connections are located on the robot as shown in the figure.
Customer connection upper arm.
A B C
xx0800000289
A Air M16x1.5 (24° cone sealing)

B R2.CP
C R2.CS
Customer connections base
xx0800000288
A R1.CP/CS
B Air M16x1.5
C R1.CBUS
D R1.SMB

Continued
Extra equipment connections

Connections to the:
• air hose ( 3/8") is located on the front part of the upper arm and at the base.
Max. 8 bar. Inner hose diameter: 9.5 mm.
• signal cabling (option) is located on the front of the upper arm.
Number of signals, customer connections R1.CP/CS:
• 23 (50V, 0.5A)
• 9 (300V, 2A). 8 are double crimped in R1.CP/CS and one is only accessible
in the robot base.
• 2 DeviceNet or Profibus R1.CP/CS
• One protective ground
Number of signals, customer connections R1.CBUS:
• 4 EtherNet R1.CBUS
Connection sets
To connect power and signal conductors to the robot base/upper arm connectors,
the following parts are recommended.
Connection Connector Art. no. Content
set
PROC1 on R1.CP/CS 3HAC16667-1 • Sockets for cable area of 0.14-2.5
base mm²
• Hood foundry
• Hinged frame, hood
• Multicontact-module, female
Connector set R1.CP/CS 3HAC033181-001 • Hose coupling
on base • M12 connector, male
R2.CP/R2.CS R2.CP/R2.CS 3HAC025396-001 • Pins for cable area 0.21 - 0.93
mm²
• Bottle shaped shrinking hose
• Angle shaped shrinking hose

2.8.3 Customer connections on upper arm
Customer connections on upper arm

The figure shows the customer connections on the upper arm, including the optional
signal lamp that can be fitted to the armhouse.
B C D
xx0800000290
A Signal lamp
B R3.H1 +, R3.H2 -
C R2.CP
D R2.CS
Power supply connections on upper arm
Signal name Customer Ter- Customer Contact Customer Contact on robot base
minal Controller on Upper arm, R2 (cable between robot and controller
not supplied)
CPA XP6.1 R2.CP.A R1.CP/CS.d1
CPB XP6.2 R2.CP.B R1.CP/CS.d6
CPC XP6.3 R2.CP.C R1.CP/CS.d3
CPD XP6.4 R2.CP.D R1.CP/CS.d4
CPE XP6.1 R2.CP.E R1.CP/CS.d1
CPF XP6.2 R2.CP.F R1.CP/CS.d6
CPG R2.CP.G (Earth)
CPH - R2.CP.H R1.CP/CS.d7
CPJ XP6.3 R2.CP.J R1.CP/CS.d3
CPK XP6.4 R2.CP.K R1.CP/CS.d4

Continued
Signal connection on upper arm
Signal name Customer Ter- Customer Contact Customer Contact on robot base
minal Controller on Upper arm, R2 (cable between robot and controller
not supplied)
CSA XP5.1.1 R2.CS.A R1.CP/CS.b1
CSB XP5.1.2 R2.CS.B R1.CP/CS.b2
CSC XP5.2.1 R2.CS.C R1.CP/CS.b3
CSD XP5.2.2 R2.CS.D R1.CP/CS.b4
CSE XP5.2.3 R2.CS.E R1.CP/CS.b5
CSF XP5.2.4 R2.CS.F R1.CP/CS.b6
CSG XP5.1.9 R2.CS.G R1.CP/CS.b7
CSH XP5.1.10 R2.CS.H R1.CP/CS.b8
CSJ XP5.1.11 R2.CS.J R1.CP/CS.b9
CSK XP5.1.12 R2.CS.K R1.CP/CS.b10
CSL XP5.1.3 R2.CS.L R1.CP/CS.b11
CSM XP5.1.4 R2.CS.M R1.CP/CS.b12
CSN XP5.1.5 R2.CS.N R1.CP/CS.b13
CSP XP5.1.6 R2.CS.P R1.CP/CS.b14
CSR XP5.3.1 R2.CS.R R1.CP/CS.b15
CSS XP5.3.2 R2.CS.S R1.CP/CS.b16
CST XP5.3.3 R2.CS.T R1.CP/CS.b18
CSU XP5.3.4 R2.CS.U R1.CP/CS.b19
CSV XP5.3.5 R2.CS.V R1.CP/CS.b20
CSW XP5.3.6 R2.CS.W R1.CP/CS.b21
CSX XP5.2.9 R2.CS.X R1.CP/CS.b22
CSY XP5.2.10 R2.CS.Y R1.CP/CS.b23
CSZ XP5.2.11 R2.CS.Z R1.CP/CS.b24

3 Maintenance
3.1 Introduction
3 Maintenance
3.1 Introduction
Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB
4600.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided according to the
maintenance activity.
Safety information
Observe all safety information before conducting any service work!
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 21 before performing any service
work!
Note
If the IRB 4600 is connected to power, always make sure that the IRB 4600 is
connected to protective earth before starting any maintenance work!

3 Maintenance
3.2.1 Specification of maintenance intervals
3.2 Maintenance schedule
3.2.1 Specification of maintenance intervals
Introduction
The intervals are specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the IRB 4600:
• Calendar time: specified in months regardless of whether the system is
running or not.
• Operating time: specified in operating hours. More frequent running means
more frequent maintenance activities.
• SIS: specified by the robot's SIS (Service Information System). A typical
value is given for a typical work cycle, but the value will differ depending on
how hard each part is run. The SIS used in M2004 is further described in the
Operating manual - Service Information System.
Overhaul
Depending on application and operational environment a complete overhaul may
be necessary in average around 40000 hours.
ABB Connected Services and its Assessment tools can help you to identify the
real stress level of your robot, and define the optimal ABB support to maintain your
robot working.
Contact your local ABB Customer Service to get more information.

3 Maintenance
3.2.2 Maintenance schedule
General
The robot must be maintained regularly to ensure proper function. The maintenance
activities and intervals are specified in the following table.
Non-predictable situations also give rise to inspections of the robot. Any damages
must be attended to immediately!
The inspection intervals do not specify the life of each component. Values for these
are specified in the section Expected component life on page 125
Instructions for how to perform the different maintenance activities are found in
sections:
• Inspection activities on page 126
• Replacement activities on page 160
• Cleaning activities on page 200
Activities and intervals, standard equipment

The following table specifies the required maintenance activities and intervals.
Maintenance activity Equipment Interval
Cleaning Robot Cleaning the IRB 4600 on page 200
Inspection Oil level in axis-1 gearbox Every 12 months.
Inspection Oil level in axis-5-6 gearbox Every 12 months.
Inspection Robot harness Every 12 months i .
Inspection Information labels Every 12 months.
Inspection Dampers Every 12 months.
Inspection Pressure relief valve Every 12 months ii .
Inspection Mechanical stop Every 12 months.
Change Oil in axis-1 gearbox First change when DTC iii reads:
• 6,000 hours
Second change when DTC iii reads:
• 24,000 hours
Following changes:
• Every 24,000 hours.
• 6,000 hours
• 24,000 hours
Following changes:

3 Maintenance
Continued
Maintenance activity Equipment Interval

• 6,000 hours
• 24,000 hours
Following changes:
Change Oil in axis-4 gearbox No change needed.
Change Oil in axis-5-6 gearbox First change when DTC iii reads:
• 6,000 hours
• 24,000 hours
Following changes:
Overhaul Robot Every:
• 40,000 hours .
Replacement Battery pack, measurement 36 months or battery low alert iv
system of type RMU101 or
RMU102 (3-pole battery con-
tact)
Replacement Battery pack, measurement Battery low alert v
system with 2-pole battery
contact, e.g. DSQC633A
i Replace when damage or cracks is detected or life limit is approaching that specified in section
Expected component life on page 125.
ii Check more often if the environment is very contaminated.
iii DTC = Duty Time Counter. Shows the operational time of the robot.
iv The battery low alert (38213 Battery charge low) is displayed when the battery needs to be replaced.
The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned
on until the battery is to be replaced.
See the replacement instruction for more details.
v The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the
robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime
can be extended with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.
Activities and intervals, optional equipment

The following table specifies the required maintenance activities and intervals for
common optional equipment. The maintenance of other external equipment for the
robot is detailed in separate documents.
Maintenance activity Equipment Interval Note
Inspection Signal lamp Every:
12 months
Inspection 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.

3 Maintenance
3.2.3 Expected component life
3.2.3 Expected component life
General
The expected life of a specific component of the robot can vary greatly depending
on how hard it is run.
Expected component life - protection type Standard
Component Expected life Note

Cable harness 40,000 hours ii Not including:
Normal usage i • Possible SpotPack
harnesses
• Optional upper arm
harnesses
Cable harness 20,000 hours ii Not including:
Extreme usage iii • Possible SpotPack
harnesses
• Optional upper arm
harnesses
Gearboxes iv 40,000 hours
i Examples of "normal usage" in regard to movement: most material handling applications.
ii Severe chemical or thermal environments, or similar environments, can result in shortened life
expectancy.
iii Examples of "extreme usage" in regard to movement: press tending, very severe palletizing
applications, major use of axis 1 movement.
iv Depending on application, the lifetime can vary. The Service Information System (SIS), integrated
in the robot software, can be used as a guidance for planning service of gearbox for the individual
robot. This applies to gearboxes on axes 1, 2 and 3. The lifetime of gearbox axes 4, 5 and 6 is not
calculated by 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.
The SIS for an IRC5 system is described in the Operating manual - Service Information System.

3 Maintenance
3.3.1 Inspecting oil level, axis 1 gearbox
3.3 Inspection activities
Mounting position of the robot

If the robot is floor mounted, follow the procedures in Inspecting the gearbox oil
level in a floor mounted robot on page 127.
If the robot is suspended, follow the procedures in Inspecting the gearbox oil level
in a suspended robot (Other design than Type C) on page 130.
Note
If the suspended robot is design Type C, the oil level can not be inspected while
the robot is hanging upside down. To make sure that the correct amount of oil
is refilled after some repair work, make a note of how much oil was drained and
make sure to refill with the same amount. If in doubt, the suspended robot must
be dismantled from its suspended position, secured in a floor mounted position,
and then the oil level can be inspected according to Inspecting the gearbox oil
The method described in this section of inspecting the oil level in a suspended
robot is only valid for Other design than Type C.
Read more about design Type C in section Type C of IRB 4600 on page 375.
Required equipment
Equipment Note
Only valid for Other design than Type C: 3HAC029646-001
Oil plug sealing washer, gearbox
Lubrication oil See section Type of lubrication in gearboxes
on page 160.
on page 385.
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.

3 Maintenance
Continued
Inspecting the gearbox oil level in a floor mounted robot

Location of oil plugs (floor mounted)
The axis 1 gearbox is located between the frame and base of the robot. The oil
plug for inspection is shown in the figure.
Type C
xx1200000632
A Oil plug, filling and inspection

B Oil plug, draining
Other design (1) than Type C
xx0800000304
A Oil plug, inspection

B Oil plug, gearbox

3 Maintenance
Continued
A
xx1000000669
A Oil plug draining, on gearbox

B Oil plug filling, on surface for motor flange
C Surface for motor flange
Inspecting oil level, axis-1 gearbox (floor mounted)

Use this procedure to inspect the oil level in the axis-1 gearbox, when the robot is
floor mounted.
Action Note
1
WARNING
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 60.
2
DANGER
Turn off all:

to the robot, before entering the robot
working area.
3
CAUTION
The gearbox can contain an excess of

pressure that can be hazardous. Open the
oil plug carefully in order to let out the ex-
cess pressure.

3 Maintenance
Continued
Action Note
4 Open the oil plug, inspection. See Location of oil plugs (floor mounted)
on page 127.
5
Note A
Valid for Type C and Other design (1) than
Type C
Measure the oil level by looking into the hole
of the oil plug inspection.
B
Required oil level:
• 0 -5 mm, up to the lower edge of the
oil plug hole of the oil plug inspec-
tion.
xx1200000859
Parts:
A Oil plug inspection
B Approximate oil level
6
Note
Valid for Other design (2) than Type C:

Measure the oil level at the oil plug hole.
Required oil level:
• 35 ± 3 mm below the surface for the
motor flange.
The oil level shall only just start to be ob- xx1000000824
served when looking through the oil filling
hole. See figure! Parts:
• A: 35 ± 3 mm
• B: Surface for motor flange
• C: Filling hole
• D: Oil level
7 Add oil if required. How to fill oil is described in section:
• Changing the oil, axis-1 gearbox
on floor mounted robots on
page 162
8 Refit the oil plug, inspection. Tightening torque:
• 24 Nm

3 Maintenance
Continued
Inspecting the gearbox oil level in a suspended robot (Other design than Type C)
Location of oil plugs (suspended)
xx1200000883
A Oil plug, filling


A
xx1000001436
A Filling oil plug, on gearbox

B Draining oil plug, on surface for motor flange

3 Maintenance
Continued
Inspecting oil level, axis-1 gearbox (suspended robot)

Use this procedure to inspect the oil level in the axis-1 gearbox, when the robot is
suspended.
This procedure is only valid for Other design than Type C.
Note
If the suspended robot is design Type C, the oil level can not be inspected while
the robot is hanging upside down. To make sure that the correct amount of oil
is refilled after some repair work, make a note of how much oil was drained and
make sure to refill with the same amount. If in doubt, the suspended robot must
be dismantled from its suspended position, secured in a floor mounted position,
and then the oil level can be inspected according to Inspecting the gearbox oil
Note
If the suspended robot is Other design than Type C, and the axis-1 gearbox is
filled with an amount of oil suited for an inverted position, the oil level can only
be inspected in the inverted position! If the robot was taken down to stand on
the floor, the oil level would be above the oil plug hole, which would result in oil
leakage if the plug would be opened while robot stands on the floor!
Action Note
1
WARNING

2
DANGER
Turn off all:

working area.
3
CAUTION

cess pressure.

3 Maintenance
Continued
Action Note
4 Open the oil plug inspection on the axis 1 See the figure in:
gearbox. • Location of oil plugs (floor moun-
ted) on page 127
5 Required oil level:
• up to the lower edge of the oil plug
hole.
Note
The oil plugs on gearbox axis 1 are now on

top.
xx1100000008

page 162
7 Refit the oil plug. Tightening torque:
• 3-8 Nm
Note
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.

3 Maintenance
3.3.2 Inspecting the oil level, axis 2 gearbox
Location of axis 2 gearbox

The axis 2 gearbox is located in the lower arm rotational center, underneath the
motor attachment. The oil plugs are shown in the figure.
xx0800000305
A Oil plug, filling

B Oil plug, draining (Quick connect fitting)
Required equipment
Equipment Note
on page 160.
Oil plug (Quick connect fitting) For article number see Spare part lists on
page 391.
on page 385.

3 Maintenance
Continued
Inspecting oil level, axis 2 gearbox

Use this procedure to inspect the oil level in the axis 2 gearbox.
Action Note
1
WARNING

2
DANGER
Turn off all:

working area.
3
CAUTION

cess pressure.
4 Open the correct oil plug depending on how See the figure in:
the robot is fitted: • Location of axis 2 gearbox on
• Floor mounted: oil plug, filling page 133
• Suspended: oil plug, draining (Quick
connect fitting)
Note
Always open the oil plug on top, depending

how the robot is fitted!
5 Measure the oil level at the oil plug hole.

Required oil level:
• 42 mm ± 5 mm below the lower edge
of the oil plug hole.
6 Add oil if required. How to fill oil is described in section
on page 174
7 Refit the oil plug, filling. Tightening torque:
• 24 Nm
Note

leakage.

3 Maintenance

The axis 3 gearbox is located in the upper arm rotational center, underneath the
motor attachment. The oil plug for inspection is shown in the figure.
Type C
xx1200000633
A Oil plug, armhouse (Not visible in this figure. See enlarged figure!)
B Oil plug, armhouse

3 Maintenance
Continued
Other design than Type C
xx0800000306
A Oil plug, armhouse

B Oil plug, gearbox (not visible in this figure)
Required equipment
Equipment Note
on page 160.
on page 385.
Inspecting the oil level, axis 3 gearbox

Action Note
1
WARNING

- Safety risks during work with gearbox lub-
ricants (oil or grease) on page 60.
2 Move the robot to where the upper arm is

placed in a +30° position.

3 Maintenance
Continued
Action Note
3
DANGER
Turn off all:

ing area.
4
CAUTION
The gearbox can contain an excess of pres-

sure that can be hazardous. Open the oil plug
carefully in order to let out the excess pres-
sure.
5 Type C: Open the oil plug, armhouse (pos. See the figure in:
B). • Location of axis 3 gearbox on
Other design than Type C: Open the oil plug, page 135
armhouse.
Required oil level:
• oil in the gearbox shall be just below
the edge of the oil plug hole.
on page 178
• Other design than Type C, in
armhouse: 10 Nm
Other design than Type C, in
gearbox: 3 Nm
Type C, both plugs: 10 Nm

3 Maintenance

The axis 4 gearbox is located in the upper armhouse. The oil plug is shown in the
figure.
xx0800000307
A Oil plug, for filling and draining
Required equipment
Equipment Note
on page 160.
on page 385.
Inspecting the oil level, axis 4 gearbox

Action Note
1
WARNING


3 Maintenance
Continued
Action Note
2 Move the robot to where the upper arm points
straight up and the oil plug hole is on top of
the axis 4 gearbox.
3
DANGER
Turn off all:

ing area.
4
CAUTION

sure.
5 Open the oil plug. See the figure in:

• Location of axis 4 gearbox on
page 138
Required oil level:
• 35 ± 5 mm below the oil plug flange.
on page 185
8 Refit the oil plug, filling. Tightening torque:
• 10 Nm

3 Maintenance
3.3.5 Inspecting oil level, gearbox axes 5 - 6
Location of gearbox, axes 5-6

The gearbox axes 5-6 is located in the wrist unit. The oil plug is shown in the figure.
The figure shows IRB 4600 -60/2.05, -45/2.05, -40/2.55 with wrist 60 kg
xx0800000308
A Oil plug, tilthouse

B Oil plug, wrist (also used as air inlet when draining from oil plug A)
The figure shows IRB 4600 -20/2.50 with wrist 12/20 kg
xx0900000139


3 Maintenance
Continued
Required equipment
Equipment Note
on page 160.
on page 385.
Inspecting oil level, gearbox axes 5-6 - wrist 60 kg

Use this procedure to inspect the oil level in gearbox axes 5-6.
Action Note
1
WARNING


placed in its calibration position.
3
DANGER
Turn off all:

ing area.
4
CAUTION

sure.
5 Open the oil plug, wrist. See the figure in:

• Location of gearbox, axes 5-6 on
page 140
• 3 ±3 mm below the edge of the oil plug Note
hole.
Open the oil plug, tilthouse when inspect-
ing. This will level up oil in axes 5 and 6.
See the figure in:
• Inspecting oil level, gearbox axes
5 - 6 on page 140

3 Maintenance
Continued
Action Note
7 Add oil if required. How to fill oil is decribed in section:
• Changing oil, axes-5 and -6 gear-
boxes on page 189
8 Refit the oil plugs. Tightening torque:
• 10 Nm
Inspecting oil level, gearbox axes 5-6 alternative method - wrist 60 kg

Use this procedure to inspect the oil level in gearbox axes 5-6 as an alternative
method.
Action Note
1
WARNING


placed in its calibration position.
3 Move the upper arm (axis 3) to a horizontal This will put the oil plug, wrist on top.
position, then rotate (axis 4) +90°. See the figure in:
page 140
Note
In this position it is not possible to open

the oil plug, tilthouse, in order to level up
oil in axes 5 and 6!
4
DANGER
Turn off all:

ing area.
5
CAUTION

sure.
6 Open the oil plug, wrist. See the figure in:

page 140

3 Maintenance
Continued
Action Note
• 63 ±3 mm below the edge of the oil
plug hole.
boxes on page 189
9 Refit oil plug, wrist. Tightening torque:
• 10 Nm
Inspecting oil level, gearbox axes 5-6 - wrist 12/20 kg

Use this procedure to fill oil in the gearbox.
Action Note
1 Move the robot to a position where the upper
arm is close to horizontal and axis 4 in the
calibration position.
2
DANGER
Turn off all:

ing area.
3
CAUTION

sure.
4 Remove the oil plug, wrist. See the figure in:

page 140
• 3 ± 3 mm from the lower edge of the
oil plug in the wrist house. Open the
oil plug in the tilthouse to allow the oil
level between axis 5 and 6 to level.
6 If necessary, refill oil. How to fill oil is described in section:
boxes on page 189
• 10 Nm

3 Maintenance
3.3.6 Inspecting the cable harness
Location of cable harness

The figure shows the location of the cable harness.
xx0900000012
A Bracket, lower arm

B Cable harness
C Hole in lower arm
D Bracket, lower arm
E Cable straps steel (One not visible here)
F Bracket, frame
G Cable strap plastic, lower arm
H Bracket, armhouse
Required equipment
Equipment Note
on page 385.
Circuit diagram See chapter Circuit diagram on page 393.

3 Maintenance
Continued
Inspecting the cable harness

Use this procedure to inspect the cable harness. The inspection points are shown
in the figure Location of cable harness on page 144
Action Note
1
DANGER
Turn off all:

ing area.
2 Make an overall visual inspection of the cable

harness in order to detect wear or damage.
3 Check the connectors at the base.
4 Check the connectors at the armhouse.
5 Check all brackets and straps are properly
attached to the robot.
6 Replace the cable harness if wear, cracks or How to replace the cable harness is de-
damage is detected. scribed in Repair on page 203.

3 Maintenance
3.3.7 Inspecting information labels
Location of information labels

The figure shows the location of the information labels to be inspected.
Type C
K J
xx1200000519
A Warning - Symbol of flash

B Warning - Risk of tipping
C Label - Lifting instruction
D Warning - High temperature
E Label - Max. air pressure
F Warning - Brake release unit
G Label - Calibration
H AbsAcc Information Sign
J UL-Label
K Oil quality

3 Maintenance
Continued
xx1000000197
A Warning - Symbol of flash (4 pcs)

B Warning - Risk of tipping
C Label - Lifting instruction
D Warning - "High temperature" (2 pcs)
E Label - Max. air pressure
F Warning - Brake release unit
G Label - Calibration
H Label - Suspended robot
Required equipment
Equipment Spare part number Note

Labels For spare part number of a Labels are sold separately.
specific label see Spare part
lists on page 391.
Inspecting labels
Use this procedure to inspect the labels on the robot.
Action Note
1
DANGER
Turn off all:

ing area.

3 Maintenance
Continued
Action Note
2 Check all labels. See the figure in Location of information
labels on page 146.
3 Replace any missing or damaged labels.

3 Maintenance
3.3.8 Inspecting the mechanical stop pin, axis 1
Location of mechanical stop pin, axis 1

The mechanical stop pin is located on the frame as shown in the figure.
xx0800000298
A Fixed stop
B Mechanical stop pin, axis 1
Required equipment
Equipment Art. no. Note

Mechanical stop pin axis 1 See Spare part lists on
page 391.
Standard toolkit Content is defined in section
Standard tools on page 385.
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.

3 Maintenance
Continued
Inspection of mechanical stop pin, axis 1

Use this procedure to inspect the mechanical stop pin, axis 1.
Action Note
1
DANGER
Turn off all:

ing area.
2 Regularly check that the mechanical stop pin See the figure in:
is not bent or damaged in any other way. • Location of mechanical stop pin,
axis 1 on page 149
3 How to replace the stop pin is described
Note in section Replacing stop pin axis 1 on
page 295.
If the mechanical stop pin has been deformed
or damaged, it must be replaced.
4 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

3 Maintenance
Continued
Action Note
5 Check that the mechanical stop pin can move
freely in both directions and the bracket
works as it is supposed to.
xx1000000222

3 Maintenance
3.3.9 Inspecting additional mechanical stops
Location of additional mechanical stops

The figure shows the location of the additional stops.
D, E
xx0800000273
A Movable mechanical stop. Limited to -129°

B Movable mechanical stop. Limited to +16.5°
C Movable mechanical stop. Limited to -16.5°
D Attachment screws
E Washers
Required equipment
Equipment etc. Note

Mechanical stop set, axis 1 Includes:
• Stop
• Attachment screws plus washers
• Document for movable mechanical stop
For spare part no. see chapter Spare Parts.
Standard toolkit Content is defined in section Standard tools on
page 385.
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.

3 Maintenance
Continued
Inspecting additional mechanical stops

Use this procedure to inspect the additional mechanical stops on axis 1.
Action Note
1
DANGER
Turn off all:

ing area.
2 Check the additional mechanical stops on See the figure in:

axis 1 for damage. • Location of additional mechanical
stops on page 152
3 Make sure the stops are properly attached. Tightening torque:
• 82 Nm
4 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

3 Maintenance
3.3.10 Inspecting dampers
Location of dampers
The figure shows the location of all dampers to be inspected.
xx0800000297
A Dampers axis 2
B Dampers axis 3
C Damper axis 5
Required equipment
Equipment Spare part no. Note

Damper See Spare part lists on
page 391.
Standard toolkit - Content is defined in section
Inspecting dampers
Use this procedure to inspect the dampers.
Action Note
1
DANGER
Turn off all:

ing area.

3 Maintenance
Continued
Action Note
2 Check all dampers for damage or cracks. See the figure in:
• Location of dampers on page 154
3 Check all dampers for existing impressions
larger than 2-3 mm.
4 Check attachment screws for deformation.
5 If any damage is detected the damper must
be replaced.

3 Maintenance
3.3.11 Inspecting the pressure relief valve
Location of the pressure relief valve

The figure shows the location of the pressure relief valve.
xx0900000131
A Pressure relief valve
Required equipment
Equipment Note
on page 385.
Inspecting pressure relief valve

Use this procedure to inspect the pressure relief valve.
Action Note
1
DANGER
Turn off all:

ing area.
2
DANGER
It is important to keep the pressure relief

valve open and clean. If the air pressure is
stopped up, too much pressure can be built
up which can be hazardous.

3 Maintenance
Continued
Action Note
3 Check if the pressure relief valve is contam-
inated or covered with litter.
4 Clean if necessary.
Note
Use a cloth or a brush.

3 Maintenance
3.3.12 Inspecting Signal lamp (option)
Location of signal lamp

Signal lamp is an option.
Located as shown in the figure.
B C D
xx0800000290
A Signal lamp
B R3.H1 +, R3.H2 -
C R2.CP
D R2.CS
Required equipment
Equipment Note
Signal lamp For spare parts no. see Spare parts - Spare
parts options in Product manual, spare
parts - IRB 2600.
on page 385.
Inspecting signal lamp

Use this procedure to inspect the function of the signal lamp.
Note
If the signal lamp is damaged, it shall be replaced!
Action Note
1 Check that the signal lamp is lit when motors
are put in operation ("MOTORS ON").

3 Maintenance
Continued
Action Note
2 If the signal lamp is not lit, continue tracing
the fault with the steps below.
3
DANGER
Turn off all:

ing area.
4 Check whether the signal lamp is broken. If

so, replace.
5 Check the cable connections.
6 Measure the voltage in connectors, motor 24V
axis 3.
7 Check the cabling. If a fault is detected, re-
place.

3 Maintenance
3.4.1 Type of lubrication in gearboxes
3.4 Replacement activities
Introduction
This section describes where to find information about the type of lubrication,
article number and the amount of lubrication in the specific gearbox. It also
describes the equipment needed when working with lubrication.
Type and amount of oil in gearboxes

Information about the type of lubrication, article number as well as the amount in
the specific gearbox can be found in Technical reference manual - Lubrication in
gearboxes on the Documentation DVD (released twice a year). The revision of the
manual published on the Documentation DVD, will contain the latest updates when
the Documentation DVD is released.
Before starting any inspection, maintenance, or changing activities of lubrication,
always contact the local ABB Service organization for more information.
For ABB personnel: Always check ABB Library for the latest revision of the manual
Technical reference manual - Lubrication in gearboxes, in order to always get the
latest information of updates about lubrication in gearboxes. A new revision will
be published on ABB Library immediately after any updates. Therefore the manual
published on the documentation DVD may not contain the latest updates about
lubrication.

3 Maintenance
Continued
Location of gearboxes
The figure shows the location of the gearboxes.
xx0800000311
A Axis-1 gearbox
B Axis-2 gearbox
C Axis-3 gearbox
D Axis-4 gearbox
E Axis-5 and -6 gearbox
Equipment
Equipment Note
Oil dispenser Includes pump with outlet pipe.
Use the suggested dispenser or a similar one:
• Orion OriCan article number 22590
(pneumatic)
Nipple for quick connect fitting, with o-ring Type C: Used on the axes-1 and -2 gearboxes.
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
Expansion container, gearbox axis 1 position.

3 Maintenance
3.4.2 Changing the oil, axis-1 gearbox on floor mounted robots
Floor mounted or suspended robot

Depending on whether the robot is floor mounted or suspended, the method of
changing the oil is different.
This section describes how to change the axis-1 gearbox oil in a floor mounted
robot.
Note
The method of changing oil on the axis-1 gearbox is different on Type C compared
to Other design than Type C.
Both methods are described in this section.
Changing oil in a suspended robot

How to change the oil in a suspended robot see Changing the oil, axis-1 gearbox
on suspended robots on page 168.
Location of oil plugs

The axis 1 gearbox is located between the frame and base of the robot.
The oil plugs of the different types, are shown in the figures.
Type C
Note
Only valid for type C.

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.

3 Maintenance
Continued
xx1200000632
A Oil plug, filling and inspection

(Also used for filling if an oil dispenser is used.)
Note
Use correct oil plugs for filling and draining depending on which position the
robot is mounted:
Floor mounted:
• Draining = Oil plug on gearbox.
Mounted in suspended position:
• Draining and filling = Oil plug on surface for motor flange.

3 Maintenance
Continued
xx0800000304
A Oil plug, filling

A
xx1000000669
A Oil plug, draining

B Oil plug, filling

3 Maintenance
Continued
Required equipment
Equipment Note
Lubricating oil See section Type of lubrication in gearboxes
on page 160
Oil collecting vessel The capacity of the vessel must be sufficient
to take the complete amount of oil.
Oil dispenser One example of oil dispenser can be found
in section:
• Type of lubrication in gearboxes on
page 160
on page 385.
Draining, axis-1 gearbox

Use this procedure to drain the gearbox of oil.
Tip
In order to save time, a pneumatic oil dispenser can be used to suck out the oil
from the gearbox. Follow the instructions below!
Action Note
1
DANGER
Turn off all:

working area.
2
WARNING

3
CAUTION

cess pressure.

3 Maintenance
Continued
Action Note
4 Put an oil collecting vessel as close as For the capacity of vessel, see section:
possible to the draining hole placed in: • Type of lubrication in gearboxes on
• Type C: the base. page 160
• Other design than Type C: the
gearbox.
5 Only valid for Other design than Type C: See the figure in:
Replace oil plug draining quickly with a • Location of oil plugs on page 162
nipple (M10x1.5) where a draining hose is
fitted. Note
Draining is time-consuming.
Elapsed time varies depending on the
temperature of the oil.
6 Connect the oil dispenser. One example can be found in section:

page 160
7 Open the oil plug filling. See the figure in:
• Location of oil plugs on page 162
WARNING
If the oil plug filling is not open when the oil

dispenser is working, there is a risk of
damaging vital parts in the gearbox!
8 Using a low air pressure, start sucking the

oil out from the gearbox with the oil ejector
equipment.
9 Only valid if an oil dispenser is not used:
If an oil dispenser is not used, open the oil Note
plug draining and drain oil into an oil collect-
ing vessel. Time consuming activity!
10
WARNING
Used oil is hazardous material and must be

disposed of in a safe way. See section De-
commissioning on page 371 for more inform-
ation.
11
Note
There will be some oil left in the gearbox

after draining.
12 Refit the oil plug draining. See the figure in:

Note Tightening torque:
• Other design than Type C: 3-8 Nm
Only valid for Other design than Type C: Type C: 24 Nm
leakage.

3 Maintenance
Continued
Filling oil, axis-1 gearbox

Use this procedure to fill the gearbox with oil.
Action Note
1
DANGER
Turn off all:

area.
2
WARNING

risks. Before proceeding, please read the safety
information in the section WARNING - Safety
risks during work with gearbox lubricants (oil
or grease) on page 60.
3
CAUTION
The gearbox can contain an excess of pressure

that can be hazardous. Open the oil plug care-
fully in order to let out the excess pressure.
4 Open the oil plug, filling. See the figure in;

5 Refill the gearbox with lubrication oil. The type and amount of oil in the
gearbox is detailed in section:
Note • Type of lubrication in gear-
boxes on page 160
The exact amount of oil to be filled depends on
the amount previously being drained.
6 Inspect the oil level. How to inspect the oil level is de-
scribed in section:
• Inspecting oil level, axis 1
gearbox on page 126
• 24 Nm
Note

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.

3 Maintenance
3.4.3 Changing the oil, axis-1 gearbox on suspended robots
Floor mounted or suspended robot

Depending on whether the robot is floor mounted or suspended, the method of
changing the oil is different.
How to change oil if the robot is floor mounted, see Changing the oil, axis-1 gearbox
on floor mounted robots on page 162.
Note
The method of changing oil on the axis-1 gearbox is different on Type C compared
to Other design than Type C.
Note
Only valid for Type C!

If the robot has design Type C the basic method to change oil in a suspended
robot of this type, when still mounted in a suspended position, is to fill the same
amount of oil that was drained. Measure the amount of oil that was drained and
make a note of the result. The same amount shall later be refilled.

The axis-1 gearbox is located between the frame and base of the robot. The oil
plugs are shown in the figures.
Note
Use correct oil plugs for filling and draining depending on which position the
robot is mounted:
Floor mounted:
• Draining = Oil plug on gearbox.
Mounted in suspended position:
• Draining = Oil plug on surface for motor flange.

3 Maintenance
Continued
Other design than Type C:
xx1200000883
A Oil plug, venting

B Oil plug, draining and filling
Type C:
A
xx1000001436
A Oil plug for filling and venting

B Oil plug for draining
C Motor flange
Required equipment
Equipment Note
Lubricating oil See section Type of lubrication in gearboxes
on page 160
in section:
page 160

3 Maintenance
Continued
Equipment Note
Oil change equipment See section Special tools on page 386
Hose Used with the oil dispenser
on page 385.

Tip
In order to save time, a pneumatic oil dispenser can be used to suck out the oil
from the gearbox. Follow the instructions below!
Action Note
1
DANGER
Turn off all:

working area.
2
WARNING

3
CAUTION

cess pressure.
4 Connect the oil dispenser to the oil plug for See Required equipment on page 169.
draining. See Location of oil plugs on page 168.
5 Put the end of the hose in an oil collecting The capacity of the vessel must be suffi-
vessel. cient to take the complete amount of oil.
6 Open the end plug of the hose.
7 Open the oil plug, venting. See Location of oil plugs on page 168.
8 Using a low air pressure, start sucking the
oil out from the gearbox with the oil change
equipment.

3 Maintenance
Continued
Action Note
9
WARNING

ation.
10 Let the oil drain until the gearbox is empty.

Tip
Note
Make a note how much oil was drained.
There will be some oil left in the gearbox The same amount shall later be refilled.
after draining. Measure the volume of the
drained oil in the vessel.
11 Remove the hose and clean it.

Note
Only valid for Type C!

The basic method to change oil in a suspended robot of this type, when still
mounted in a suspended position, is to fill the same amount of oil that was
drained.
The only way to inspect the oil level after some repair work, is to make a note
how much oil was drained and to refill with the same amount. If in doubt, the
suspended robot must be dismantled from its inverted position and the oil being
inspected with the robot in a floor mounted position.
Action Note
1
DANGER
Turn off all:

area.
2
WARNING


3 Maintenance
Continued
Action Note
3
CAUTION

4 Verify that the hose of the oil change equipment See Location of oil plugs on page 168.
is clean and then fit the quick connection to the
oil plug for filling.
5 Open the oil plug for venting. See Location of oil plugs on page 168.
6 Prepare oil change equipment with the same Where to find type of oil and total
amount of lubrication oil that was drained. amount is detailed in Type and
amount of oil in gearboxes on
Note page 160.
The amount of oil to be filled depends on the

amount previously being drained.
7 Inspect the oil level. How to inspect the oil level is de-
scribed in section:
• Inspecting oil level, axis 1
gearbox on page 126
8 Disconnect the oil change equipment and put
on the protective hood on the oil plug.
9 Refit the oil plug for venting. Tightening torque:
• Other design than Type C: 3-8
Note Nm
Type C: 24 Nm
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.
Expansion container axis-1 gearbox, suspended mounted robots
Note
Not valid for Type C!

Expansion container is not needed on Type C.

3 Maintenance
Continued
When the robot is fitted in a suspended mounted position, an expansion container

for oil must be fitted on gearbox axis 1.
xx0900000129
A Expansion container
Note
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 109.

3 Maintenance
3.4.4 Changing the oil, axis-2 gearbox

The axis-2 gearbox is located in the lower arm rotational center, underneath the
motor attachment.
Oil plugs are shown in the figure.
xx0800000305
A Oil plug, filling (draining when suspended mounted)

B Oil plug, draining (filling when suspended mounted) (Quick connect fitting)
Required equipment
Equipment Note
Lubricating oil Information about the oil is found in Technical
reference manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on
page 160.
Nipple (TEMA IF 3820 S06) To be fitted on a hose, and then used for
draining connected to the quick connect fit-
ting.
See Location of oil plugs on page 174.
on page 385.

3 Maintenance
Continued

Action Note
1
DANGER
Turn off all:

working area.
2
WARNING

3
CAUTION

cess pressure.
4 Either See the figure in:

• connect a nipple to the quick connect • Location of oil plugs on page 174
fitting in the hole for draining
or
• remove the quick connect fitting.
5 Open the oil plug, filling. See the figure in:
Note
Drainage will be quicker if the oil plug,

filling is removed.
6 Drain the gearbox oil using an oil collecting

vessel. Note
7
WARNING

ation.

3 Maintenance
Continued
Action Note
8
Note
There will be some oil left in the gearbox

after draining.
9 Refit oil plug. Tightening torque:

• 24 Nm
Note

leakage.

Action Note
1
DANGER
Turn off all:

working area.
2
WARNING

3
CAUTION

cess pressure.
4 Open oil plug, filling. See the figure in:

5 Refill the gearbox with lubrication oil. Where to find type of oil and total amount
is detailed in Type and amount of oil in
Note gearboxes on page 160.
The amount of oil to be filled depends on


3 Maintenance
Continued
Action Note
6 Inspect the oil level. How to inspect the oil level is described
in section:
• Inspecting the oil level, axis 2
gearbox on page 133
7 Refit oil plug. Tightening torque:
• 24 Nm
Note

leakage.

3 Maintenance

The axis-3 gearbox is located in the upper arm rotational center.
Oil plugs are shown in the figure.
Type C
xx1200000633
A Oil plug, armhouse (not visible in this figure)

B Oil plug, armhouse

3 Maintenance
Continued
xx0800000306
A Oil plug, armhouse

B Oil plug, gearbox (not visible in this figure)
Required equipment
Equipment Note
Lubricating oil Information about the oil is found in Technical
reference manual - Lubrication in gearboxes.
See Type and amount of oil in gearboxes on
page 160.
in section:
page 160
Funnel
xx1200000862

on page 385.

3 Maintenance
Continued

There is an alternative method to drain the gearbox. See Draining - alternative
method on page 181.
Action Note
1 Move the robot to an upright position as shown
in the figure.
xx0800000327
• A: Oil collecting vessel

2
DANGER
Turn off all:

area.
3
WARNING

4
CAUTION

5 Open the oil plug, armhouse See the figure in:


3 Maintenance
Continued
Action Note
6 Type C: Open the other oil plug in the armhouse See the figure in:
and use it as a ventilation hole. • Location of oil plugs on page 178
Other design than Type C: Open the oil plug,
gearbox and use it as a ventilation hole.
vessel. Note
8
WARNING

disposed of in a proper way. See section De-
commissioning for more information.
9 Refit oil plugs. Tightening torque:

Other design than Type C, in arm-
house: 10 Nm
Other design than Type C, in gear-
box: 3 Nm
Draining - alternative method

Use this procedure to drain the oil from the gearbox, as an alternative method.
If this method is used, oil must be sucked out of the gearbox using an oil dispenser.
Action Note
1 Move the upper arm of the robot to a position See the figure in:
where the oil plug, gearbox is pointing at the • Location of oil plugs on page 178
floor.
2
DANGER
Turn off all:

area.
3
CAUTION


3 Maintenance
Continued
Action Note
4 Use an oil dispenser fitted to the oil plug, gear- An example of oil dispenser is detailed
box to drain the oil. in section:
• Type of lubrication in gear-
boxes on page 160
See the figure in:
5 Replace the oil plug, gearbox with a nipple See the figure in:
where a draining hose is fitted. • Location of oil plugs on page 178
6 Connect the oil dispenser. One example can be found in section:
• Type of lubrication in gear-
boxes on page 160
7 Open the oil plug, armhouse now pointing up- See the figure in:
wards and use it as a ventilation hole. • Location of oil plugs on page 178
WARNING
The oil plug, gearbox must be open

when the oil dispenser equipment is
used! Otherwise sealings and other
parts will be damaged.
8 Start sucking the oil out from the gearbox with For capacity of the vessel see section:
the oil ejector equipment. • Type of lubrication in gear-
boxes on page 160
9
WARNING

disposed of in a proper way. See section De-
commissioning for more information.
10
Note
There will be some oil left in the gearbox after

draining!
11 Refit the oilplugs. See the figure in:

Tightening torque:
house: 10 Nm
box: 3 Nm

3 Maintenance
Continued

Action Note
1 Move the upper arm to a position where the
wrist is pointing towards the floor as shown in
the figure.
xx0800000329
2
DANGER
Turn off all:

area.
3
WARNING

4
CAUTION

5 Open the oil plug, armhouse. See the figure in:

6 Refill the gearbox with lubricating oil. Where to find type of oil and total
amount is detailed in Type and
amount of oil in gearboxes on
Tip page 160.
Use a funnel.
Note
The amount of oil to be filled depends on the

amount previously being drained.

3 Maintenance
Continued
Action Note
7 Inspect the oil level. How to inspect oil is described in
section:
• Inspecting the oil level, axis 3
gearbox on page 135
house: 10 Nm
box: 3 Nm

3 Maintenance

The axis-4 gearbox is located in the front of the upper armhouse.
The oil plug is shown in the figure.
xx0800000307
A Oil plug, for filling and draining
Required equipment
Equipment Note
Lubricating oil Where to find information of the type of oil,
article number and the amount in the gear-
box, see section Type of lubrication in gear-
boxes on page 160
Plastic hose 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

3 Maintenance
Continued
Equipment Note
on page 385.
Draining oil
Use this procedure to drain oil from the gearbox.
Action Note
1 Move the robot to the position shown in the
figure.
xx0800000328
• A: Oil collecting vessel

2
DANGER
Turn off all:

working area.
3
WARNING

4
CAUTION

cess pressure.
5 Open oil plug, draining. See the figure in:


3 Maintenance
Continued
Action Note
vessel. Note
Tip
Insert a compressed air hose approximately
100 mm into the gearbox, to vent the gear-
box.
This speeds up the draining significantly.
7
WARNING

ation.
8 Refit the oil plug. Tightening torque: 10 Nm.
Filling oil
Action Note
1 Move the upper arm to the position shown
in the figure.
xx0800000330
2
DANGER
Turn off all:

working area.

3 Maintenance
Continued
Action Note
3
WARNING

4
CAUTION

cess pressure.
5 Open the oil plug, filling. See the figure in:

6 Refill the gearbox with lubricating oil. Where to find type of oil and total amount
gearboxes on page 160.
Tip
Use a funnel.
Note

7 Refit the oil plug. Tightening torque: 10 Nm.

3 Maintenance
3.4.7 Changing oil, axes-5 and -6 gearboxes

The axes-5 and -6 gearboxes are located in the wrist unit.
The oil plug is shown in the figure.
The figure shows wrist variant 60 kg
xx0800000308

B Oil plug, wrist unit (also used as air inlet when draining from oil plug A)

3 Maintenance
Continued
The figure shows wrist variant 12/20 kg
xx0900000139

Note
The gearboxes for axes-5 and -6 are the same.
Required equipment
Equipment Note
Lubrication oil Where to find information of the type of oil,
article number and the amount in the gear-
box, see section: Type of lubrication in gear-
boxes on page 160
on page 385.
Draining axes-5 and -6 gearbox - wrist 60 kg

CAUTION
The gearbox can contain an excess of pressure that can be hazardous. Open
the oil plug carefully in order to let out the excess pressure.
Action Note
1 Move the upper arm to a position where it
points downwards.

3 Maintenance
Continued
Action Note
2 Move axis 5 to a position where the oil plug, The turning disk shall be in a horisontal
tilthouse points downwards. position.
3
DANGER
Turn off all:

working area.
4
WARNING

5 Put an oil collecting vessel under the wrist The capacity of the vessel must be suffi-
in order to collect drained oil. cient to take the complete amount of oil.
6 Open the oil plug, tilthouse. See the figure in:
7 Open the oil plug, wrist (air inlet). See the figure in:
This is done for the ventilation of the gear- • Location of oil plugs on page 189
box and to fascilitate draining.
8 Drain the gearbox.
Note
9
WARNING

ation.
Draining axes-5 and -6 gearbox - wrist 12/20 kg

CAUTION

3 Maintenance
Continued
Action Note
1 Move the upper arm to a horizontal position.
2 Turn axis-4 to the calibration position.
3
DANGER
Turn off all:

working area.
4
WARNING

5 Remove the oil plugs in the wrist. See the figure in:
6 Turn axis-4 through 90° so that the oil plug
on the side of the wrist points downwards.
7 Then turn axis-4 another 90°.
8 Let the remaining oil run out through the oil
plug hole, tilthouse.
Filling oil axes-5 and -6 gearbox - wrist 60 kg

CAUTION
Action Note
1 Move the upper arm to a position where the See the figure in:
oil plug, wrist points upwards. • Location of oil plugs on page 189
2 Move axis-5 to a position where the oil plug, See the figure in:
tilthouse points upwards. • Location of oil plugs on page 189
3
DANGER
Turn off all:

working area.

3 Maintenance
Continued
Action Note
4
WARNING

5 Open oil plug, wrist. See the figure in:

6 Open oil plug, tilthouse. See the figure in:
7 Refill oil using oil plug, wrist. There will be oil left in the gearbox after
draining. Therefore the amount of oil filled
Note will be less than the total amount.
When filling oil in a wrist (60 kg) begin by
There will be some oil left in the gearbox only filling 1.500 ml. Check oil level. If
after draining. needed add more oil.

in section:
5 - 6 on page 140
10 Refit both oil plugs. Tightening torque:
• 10 Nm
Filling oil axes-5 and -6 gearbox - wrist 12/20 kg

CAUTION
Action Note
1 Run the upper arm to a horizontal position.
2 Turn axis-4 to the calibration position.

3 Maintenance
Continued
Action Note
3
DANGER
Turn off all:

working area.
4
WARNING

5 Open the oil plug, tilthouse. See in figure:


in section:
5 - 6 on page 140
8
Note
If the robot is fitted in a suspended position,

the wrist should be turned 180°.
9 Refit the oil plugs. Tightening torque:

• 10 Nm

3 Maintenance
3.4.8 Replacing SMB battery
Note
The battery low alert (38213 Battery charge low) is displayed when the battery
needs to be replaced. The recommendation to avoid an unsynchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For an SMB board with 2-pole battery contact, the typical lifetime of a new battery
is 36 months if the robot is powered off 2 days/week or 18 months if the robot is
powered off 16 h/day. The lifetime can be extended for longer production breaks
with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.
WARNING
See instructions for batteries, WARNING - Safety risks during handling of batteries
on page 59.

3 Maintenance
Continued
Location of SMB battery

The SMB battery is located at the base of the robot, as shown in the figure.
DSQC 633A
xx0800000322
A SMB battery (2-pole battery contact)

B Battery cover
C Attachment screws
D SMB battery cable
E How to arrange the battery cable

3 Maintenance
Continued
RMU 101
A
B
xx1300000339
A SMB battery (3-pole battery contact)

B Battery cover
Required equipment
Note
There are two variants of SMB units and batteries. One with 2-pole battery contact
and one with 3-pole battery contact. The variant with the 3-pole battery contact
has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!
Equipment Note
SMB battery pack Battery includes protection circuits. Replace it only with given
spare part no. or an ABB approved equivalent.
See Spare part lists on page 391.
Standard toolkit Content is defined in section Standard tools on page 385.
Circuit diagram See chapter Circuit diagram on page 393.
Removing SMB battery

Use this procedure to remove the SMB battery.
Action Note
1 Move the robot to its calibration position. This is done in order to facilitate
the updating of the revolution
counter.

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

to the robot, before entering the robot working area.
3
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the

unit please read the safety information in the section
WARNING - The unit is sensitive to ESD! on page 57
4 Remove the SMB battery cover. See the figure in Location of SMB
battery on page 196.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
5 Pull out the SMB battery. See the figure in Location of SMB
6 Disconnect the battery cable and remove the bat- See the figure in Location of SMB
tery. battery on page 196.
7 How to dispose of the used SMB battery, see
chapter Decommissioning on page 371.
Refitting SMB battery

Use this procedure to refit the SMB battery.
Action Note
1
DANGER
Turn off all:

to the robot, before entering the robot working area.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the

unit please read the safety information in the section
WARNING - The unit is sensitive to ESD! on page 57
3 Reconnect the battery cable to the SMB battery. See the figure in Location of SMB

3 Maintenance
Continued
Action Note
4 Put the battery unit into its recess while arranging See the figure in Location of SMB
the SMB cables as shown in the figure. battery on page 196.
5 Secure the SMB cover with its attachment screws. See the figure in Location of SMB
6 Update the revolution counter. Detailed in Updating revolution
counters on page 349.
7
DANGER
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 53.

3 Maintenance
3.5.1 Cleaning the IRB 4600
3.5 Cleaning activities
WARNING
Turn off all electrical power supplies to the manipulator before entering its work
space.
General
To secure high uptime it is important that the IRB 4600 is cleaned regularly. The
frequency of cleaning depends on the environment in which the manipulator works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 4600.
Note
Always verify the protection type of the robot before cleaning.
Oil spills
Oil spills from gearboxes
Use the following procedure if any oil spills are detected that can be suspected to
originate from a gearbox.
1 Inspect that the oil level in the suspected gearbox is according to the
recommendations, see Inspection activities on page 126.
2 Write down the oil level.
3 Inspect the oil level again after, for example, 6 months.
4 If the oil level is decreased then replace the gearbox.
Oil spills discolors painted surfaces

Oil spills on painted surfaces of the robot can result in discoloration.
Note
After all repair and maintenance work involving oil, always wipe the robot clean
from all surplus oil.
Dos and don'ts!

This section specifies some special considerations when cleaning the robot.
Always!
• Always use cleaning equipment as specified! Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning!

3 Maintenance
Continued
Never!
• 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!
• Never remove any covers or other protective devices before cleaning the
robot!
Cleaning methods
These following table defines what cleaning methods are allowed for ABB
manipulators depending on the protection type.
Protection Cleaning method
type
Vacuum Wipe with cloth Rinse with water High pressure water or
cleaner steam
Standard Yes Yes. With light Yes. It's highly re- No
cleaning deter- commended to in-
gent. spect the fans for
contamination that
could hinder the air
supply at the regu-
lar cleaning, and
then clean if neces-
sary.
Foundry Plus Yes Yes. With light Yes. It is highly re- Yes i .
cleaning deter- commended that It is highly recommended
gent or spirit. the water contains that the water and steam
a rust-prevention contains rust preventive,
solution. without cleaning deter-
gents.
i Perform according to section Cleaning with water and steam on page 201.
Cleaning with water and steam

Instructions for rinsing with water
ABB robots with protection types Standard, Foundry Plus, Wash, or Foundry Prime
can be cleaned by rinsing with water (water cleaner). 1
The following list defines the prerequisites:
• Maximum water pressure at the nozzle: 700 kN/m 2 (7 bar) I
• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum flow: 20 liters/min I
I Typical tap water pressure and flow
Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be
cleaned using a steam cleaner or high pressure water cleaner. 2
1 See Cleaning methods on page 201 for exceptions.

2 See Cleaning methods on page 201 for exceptions.

3 Maintenance
Continued
The following list defines the prerequisites:

• Maximum water pressure at the nozzle: 2500 kN/m 2 (25 bar)
• Fan jet nozzle should be used, min. 45° spread
• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum water temperature: 80° C
Cables
Movable cables need to be able to move freely:
• Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
• Clean the cables if they have a crusty surface, for example from dry release
agents.
Cooling fans
Inspect the air supply inlet of the the motor cooling fans. Clean to remove any
contamination that could hinder the air supply.

4 Repair
4.1 Introduction
4 Repair
4.1 Introduction
Structure of this chapter

This chapter describes all repair activities recommended for the IRB 4600 and any
external unit.
It is made up of separate procedures, each describing a specific repair activity.
Each procedure contains all the information required to perform the activity, for
example spare parts numbers, required special tools, and materials.
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Otherwise damage to the mechanics and electronics may occur.
Required equipment
The details of the equipment required to perform a specific repair activity are listed
in the respective procedures.
The details of equipment are also available in different lists in the chapter Reference
information on page 377.
Safety information
There are general safety information and specific safety information. The specific
safety information describes the danger and safety risks while performing specific
steps in a procedure. Make sure to read through the chapter Safety on page 21
before commencing any service work.
Note
If the IRB 4600 is connected to power, always make sure that the IRB 4600 is
connected to earth before starting any repair work.

4 Repair
4.2.1 Performing a leak-down test
4.2 General procedures
4.2.1 Performing a leak-down test
When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.
Required equipment
Equipment, etc. Article number Note

Leak-down tester -
Leak detection spray -
Performing a leak-down test
Action Note
1 Finish the refitting procedure of the motor or gear in
question.
2 Remove the upper oil plug on the gear and replace
it with the leak-down tester.
Regulators, which are included in the leak-down test,
may be required.
3 Use caution, apply compressed air and raise the Correct value:
pressure with the knob until the correct value is 0.2-0.25 bar (20-25 kPa)
shown on the manometer.
CAUTION
The pressure must under no circumstance be higher

than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.
4 Disconnect the compressed air supply.

5 Wait for approximately 8-10 minutes and make sure If the compressed air is signific-
that no pressure loss occurs. antly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.
6 If any pressure drop occurred, then localize the leak
as described in step 7.
If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.
7 Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.
8 When the leak has been localized, take the necessary
measures to correct the leak.

4 Repair
4.2.2 Mounting instructions for bearings
General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment

Grease 3HAB3537-1 Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings

Follow the following instructions while mounting a bearing on the robot.
Action Note
1 To avoid contamination, let a new bearing remain in its wrapping
until it is time for fitting.
2 Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
3 Bearing rings, inner rings, and roller elements must not be subjec-
ted to direct impact. The roller elements must not be exposed to
any stresses during the assembly work.
Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting
a tapered bearing on the robot.
In addition to those instructions, the following procedure must be carried out to
enable the roller elements to adjust to the correct position against the race flange.
Action Note
1 Tension the bearing gradually until the recommended pre-tension is achieved.
Note
The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
2 Make sure the bearing is properly aligned as this will directly affect the durab-
ility of the bearing.
Greasing of bearings
The bearings must be greased after assembly according to the following
instructions:
• The bearings must not be completely filled with grease. However, if space
is available beside the bearing fitting, the bearing may be totally filled with
grease when mounted, as excessive grease will be pressed out from the
bearing when the robot is started.

4 Repair
Continued
• During operation, the bearing should be filled to 70-80% of the available

volume.
• Ensure that grease is handled and stored properly to avoid contamination.
Grease the different types of bearings as following description:
• Grooved ball bearings must be filled with grease from both sides.
• Tapered roller bearings and axial needle bearings must be greased in the
split condition.

4 Repair
4.2.3 Mounting instructions for seals
General
This section describes how to mount different types of seals onto the robot.
Equipment

Grease 3HAB3537-1 Used to lubricate the seals.
Rotating seals
The procedure below describes how to fit rotating seals.
CAUTION
Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.
• Keep the seal in its original wrappings or protect it well before actual
mounting.
• The fitting of seals and gears must be carried out on clean workbenches.
• Use a protective sleeve for the sealing lip during mounting, when sliding
over threads, keyways, etc.
Action Note
1 Check the seal to ensure that:
• The seal is of the correct type (provided with cutting
edge).
• There is no damage to the sealing edge (feel with a
fingernail).
2 Inspect the sealing surface before mounting. If scratches
or damage are found, the seal must be replaced since it
may result in future leakage.
3 Lubricate the seal with grease just before fitting. (Not too Article number is specified
early - there is a risk of dirt and foreign particles adhering in Equipment on page 207.
to the seal.)
Fill 2/3 of the space between the dust tongue and sealing
lip with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4 Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.

4 Repair
Continued
Flange seals and static seals

The following procedure describes how to fit flange seals and static seals.
Action
1 Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing com-
pound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
2 Clean the surfaces properly in accordance with the recommendations of ABB.
3 Distribute the sealing compound evenly over the surface, preferably with a brush.
4 Tighten the screws evenly when fastening the flange joint.
O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.
3 Check the o-ring grooves. Defective o-rings may not be used.
The grooves must be geometrically correct and
should be free of pores and contamination.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.

4 Repair
4.3.1 Removing the complete cable harness
4.3 Complete robot
Introduction
This procedure describes how to remove the complete cable harness.
How to refit the cable harness is described in section Refitting the complete cable
harness on page 222.
The removal procedure is presented in the order the work is recommended to be
performed. Therefore the order is different in the two procedures removal and
refitting of the cable harness. Cross references will make it easy to find what is
needed to know as the work continues.
The section Removing the complete cable harness consists of the following parts
presented in the order the work is recommended to be performed:
• Removal in the base Removing cable harness in base on page 212
• Removal in the frame Removing cable harness in frame on page 218
• Removal in lower arm and armhouse Removing cable harness in lower arm
and armhouse on page 219.
How to replace the SMB unit, brake release unit and motors can be found in:
• SMB unit Removing the SMB unit on page 239
• Brake release unit Removing the brake release board on page 245
• Motors Removing motors on page 298

4 Repair
Continued
Location of the cable harness

The location of the cable harness in the base, frame and lower arm is shown in the
figures.
Cable harness, base and frame.
xx0900000009
A Cover base
B Bracket
C Cable harness
D Axis-1 motor cable
E Axis-2 motor cable
F Axis-2 motor
G Axis-1 motor

4 Repair
Continued
Cable harness, lower arm.
xx0900000012

B Cable harness
C Hole in lower arm
E Cable straps, one not visible here (steel)
F Bracket, frame
G Cable strap, lower arm (plastic)
H Bracket, armhouse
Required equipment
Equipment Note
Deep well hexagon socket Width 30 mm
on page 385.

4 Repair
Continued
Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.
Depending on which routine is chosen, action might be required prior to beginning
the repair work of the robot, see the table.
Action Note
1 Decide which calibration routine to use for
calibrating the robot.
• Reference calibration. External cable
packages (DressPack) and tools can
stay fitted on the robot.
• Fine calibration. All external cable
packages (DressPack) and tools
must be removed from the robot.
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 354.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removing cable harness in base

Use this procedure to remove the cable harness in the base.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
3 Disconnect the following connectors on the
base cover:
• R1.CP/CS
• R1.MP
• R1.CBUS (if used)
Tip
xx0900000014
Do not remove the R1.SMB-connector and
air hose connector at this stage. It will be Parts:
easier to remove these two when the cover • A: R1.CP/CS
base has been removed. • B: R1.MP
• C: Air hose connector
• D: Position of R1.CBUS (if used)
• E: R1.SMB
4 Remove the cover base.
C
xx0800000456
A Base
B Cover base
C Attachment screws
5 Disconnect connectors on the brake release
unit:
• X8
• X9
• X10

4 Repair
Continued
Action Note
6 Cut the cable straps securing the battery
cable.
xx0900000099
Parts:
• A: Cable straps (2 pcs)
7 Disconnect the battery cable.
8 Unscrew the thin nut securing the R1.SMB
connector on the outside of the bracket.
Tip
Use a deep well hexagon socket, width 30

mm (like the ones used for spark plugs, or A
similar).
xx1200000888 D
C
B
xx1200000889
A Thin nut, width 30 mm

B R1.SMB
C Bracket
D Air connector
9 Unscrew the nut for the air connection on
the inside of the bracket.

4 Repair
Continued
Action Note
10 Remove the screw that secures the bracket
and unscrew the three other screws a little
just enough to be able to slide the bracket
sideways.
xx0900000100
Parts:
• A: Screw to be removed
• B: Screws to be unscrewed (3 pcs)
11 Remove the bracket by sliding it off the re-
maining three attachment screws and put
it at a 90° angle from the base.
Putting the bracket at a 90° angle facilitates
the disconnecting of cables from the
bracket.
Note xx0900000013
Use caution when performing this procedure Parts:

in order not to damage cables or other • A: Bracket at a 90° angle
components! • B: Base
12 Remove connectors and air hose connector

completely from the bracket:
• R1.CP/CS
• R1.MP
• R1.SMB
• Air hose connector
A
B
C
D
xx1200000890
A R1.CP/CS
B R1.MP
C Air hose connector
D R1.SMB
13 Remove the SMB unit from its attachment How to remove the SMB unit is described
screws. in section:
Leave the screws in the base. • Removing the SMB unit on page 239

4 Repair
Continued
Action Note
14 Disconnect connectors on the SMB unit:
• R1.SMB1-2
• R1.SMB2-6
• R2.SMB
15 Disconnect the screen connections of:
• R1.SMB1-2
• R1.SMB2-6
A
xx0900000035
Parts:
• A: Screen connection (4 pcs)
16 Disconnect the earth cables.
xx0900000015
Parts:
• A: Earth
• B: Distance screws

4 Repair
Continued
Action Note
17 Valid for Type C.
Remove the bracket securing the cable
package inside the base on the left side, by
following these steps:
• Unscrew the attachment screws just
enough to be able to remove the
bracket.
• Lift the bracket off the screws.
A
B
C
xx1200000860
Parts:
• A: Base
• B: Attachment screws
• C: Bracket
18 Valid for Other design than Type C.
Remove the bracket securing the cable
package inside the base on the left side, by
following these steps:
• Unscrew the attachment screws just
enough to be able to remove the
bracket.
• Lift the bracket off the screws.
xx0900000018
Parts:
• A: Base
• C: Bracket
19 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 218

4 Repair
Continued
Removing cable harness in frame

Use this procedure to remove the cable harness in the frame.
Tip
Before starting this procedure, first remove the cable harness in the base. See
Removing the complete cable harness on page 209.
Action Note
1
DANGER
Turn off all:

working area.
2 Disconnect the motor cables on the axis-1 How to remove the motor cables is de-
and axis-2 motors. scribed in section:
• Removing motors on page 298
3 Remove the bracket securing the cable See the figure in:
package to the frame. • Location of the cable harness on
page 210
4 Cut the cable straps securing the cable See the figure in:
harness to the frame and lower arm. • Location of the cable harness on
page 210
5 Prepare the end of the cable package in the
base with tape as shown in the figure.
Tip
A
In order to protect the connectors from
getting residual grease on the cable har-
ness, put some plastic over them prior to F
pushing it through the hole in the frame.
C
B
xx1200000886
A Tape
B Connectors to SMB unit and Brake
release unit
C R1.CP/CS
D Air hose
E R1.MP
F R1.SMB (Connector bent and taped
upwards)
4 Repair
Continued
Action Note
6 Pull out the cable package through the hole
in the frame.
Note
Use caution when performing this proced-

ure in order not to damage cables or other
components!
7 Continue the removal of the cable package How to remove the cable package from
from the lower arm and armhouse. the lower arm and armhouse is described
in section:
• Removing cable harness in lower
arm and armhouse on page 219
Removing cable harness in lower arm and armhouse

Use this procedure to remove the cable harness in the lower arm and armhouse.
Tip
Before starting this procedure, first remove the cable harness in the base
Removing the complete cable harness on page 209 and frame Removing the
complete cable harness on page 209.
Action Note
1
DANGER
Turn off all:

working area.
2 Cut the cable strap on the lower arm. See the figure in:
• Location of the cable harness on
page 210 (Cable harness, lower arm)

4 Repair
Continued
Action Note
3 Remove the brackets on the lower arm.
D
C
xx0900000020
Parts:
• A: Bracket, lower arm
• B: Bracket, lower arm
• C: Bracket, armhouse
• D: Cable bracket
4 Remove the bracket on the armhouse.
xx0800000335
Parts:
• A: Tubular shaft unit

4 Repair
Continued
Action Note
5 Remove the cable cover on the armhouse.
xx0800000338
Parts:
• A: Signal lamp
• B: Bracket
• C: Cable cover, armhouse
6 Remove signal lamp if used.
7 Continue the removal of the cable package 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:

4 Repair
4.3.2 Refitting the complete cable harness
Introduction
This procedure describes how to refit the complete cable harness.
How to remove the cable harness is described in Removing the complete cable
harness on page 209.
The refitting procedure is presented in the order the work is recommended to be
performed.
Therefore the order is different in the two procedures removal and refitting of the
cable harness. Cross references will make it easy to find what is needed to know
as the work continues.
The section Refitting the complete cable harness consists of the following parts
presented in the order the work is recommended to be performed:
• Refitting in the frame Refitting the cable harness in the frame on page 225
• Refitting in the base Refitting the cable harness in the base on page 228
• Refitting in the lower arm and armhouse Refitting the cable harness in the
lower arm and armhouse on page 234.
How to refit the SMB unit, brake release unit and motors can be found in:
• SMB unit Refitting the SMB unit on page 242
• Brake release unit Refitting the brake release board on page 246
• Motors Refitting motors on page 306

4 Repair
Continued
Location of the cable harness

The location of the cable harness in the base, frame and lower arm is shown in the
figures.
Cable harness, base and frame.
xx0900000009
A Cover base
B Bracket
C Cable harness
D Axis-1 motor cable
E Axis-2 motor cable
F Axis-2 motor
G Axis-1 motor

4 Repair
Continued
Cable harness, lower arm.
xx0900000012

B Cable harness
C Hole in lower arm
E Cable straps, one not visible here (steel)
F Bracket, frame
G Cable strap, lower arm (plastic)
H Bracket, armhouse
Required equipment
Equipment Note
Deep well hexagon socket Width 30 mm
on page 385.
Cable grease Shell Alvania WR2

4 Repair
Continued
Refitting the cable harness in the frame

Use this procedure to refit the cable harness in the frame.
Action Note
1
DANGER
Turn off all:

working area.
2 Apply cable grease on these surfaces: Cable grease is specified in:

• cable guide inside the hole • Required equipment on page 224
• the part of the cable harness that
runs through the cable guide.
3
Note
Two alternative methods to insert the cable

package in frame and base are presented
below. Chose one of the methods.
4 Use this procedure when replacing the old

cable harness:
Method 1, step 1:
Prepare the end of the cable package in the
base with tape as shown in the figure.
A
Tip
F
In order to protect the connectors from get-

ting residual grease on the cable harness,
put some plastic over them prior to pushing E
it through the hole in the frame.
C
B
xx1200000886
A Tape
B Connectors to SMB unit and Brake
release unit
C R1.CP/CS
D Air hose
E R1.MP
F R1.SMB (Connector bent and taped
upwards)

4 Repair
Continued
Action Note
cable harness:
Method 1, step 2:
Push the cable package carefully in through
the base and up through the hole in the
frame.
Note
Use caution when performing this procedure

in order not to damage cables or other
components!

cable harness:
Method 2:
Push the cable harness carefully into the
hole in the frame and out of the hole in the
base.
Perform the procedure in the following or-
der:
• R1.MP
• R1.CP/CS
• R1.SMB1-2 and R1.SMB3-6
• Air hose.
Note

components!
Tip
In order to protect the connectors from get-

ting residual grease on the cable harness,
put some plastic over them prior to pushing
it through the hole in the frame.
7 Use this procedure when fitting a new cable

harness: Note
Without removing the plastic around cables
and hose, push the cable harness through Check that cables and air hose are placed
the hole in the frame. as shown in the figure above.
Note

components!

4 Repair
Continued
Action Note
8
Note
It is vital that the position of the air hose is

correct, as shown in the figure!
xx0900000096
Parts:
• A: Cables
• B: Air hose
• C: Hole in frame
• D: Cable guide
• E: Position of the front of the robot
9 Secure the cover to the frame with its attach-
ment screws.
xx0900000016
Parts:
• A: Frame
• B: Hole in frame
• C: Cover
10 Connect the axis-1 and axis-2 motor cables. How to refit the motor cables is described
in section:
• Refitting motors on page 306

4 Repair
Continued
Action Note
11 Sort out the different cables the way they
later will be fit on the bracket in the base.
xx0900000017
Connections:
• A: Earth cables
• B: R1.SMB1-2
• C: R1.SMB3-6
• D: R2.SMB
• E: R1.CP/CS
• F: R1.MP
• G: Air hose
• H: Position of R1.CBUS (if used)
• J: R1.SMB
12 Continue the refitting of the cable harness How to refit the cable harness in the base
in the base. is described in section:
• Refitting the cable harness in the
base on page 228
Refitting the cable harness in the base

Use this procedure to refit the cable harness in the base.
Tip
Before starting this procedure, first refit the cable harness in the frame. See:
• Refitting the complete cable harness on page 222
Action Note
1
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
2 Valid for Type C.
Attach the cable harness to the bracket.
B
xx1200000861
Parts:
• A: Attachment screw and nut
• B: Bracket
• C: Cable harness
3 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

4 Repair
Continued
Action Note
4 Secure the bracket on its attachment screws The figure shows Other design than Type
in the base. C. The principle of securing the bracket
on Type C is the same.
Tip
Perform this in the following order:

• Put the attachment screws in the
holes but do not tighten them yet (if
they have been removed earlier).
• Place the bracket on the attachment
screws.
• Secure the bracket with its attach-
ment screws.
xx0900000018
Parts:
• A: Base
• B: Attachment screws (2 pcs)
• C: Bracket
5 Refit the earth cables.
xx0900000015
Parts:
• A: Earth
• B: Distance screws
6 Connect the contacts on the SMB unit:
• R1.SMB1-2
• R1.SMB3-6
• R2.SMB
7 Refit the SMB unit. How to refit the SMB unit is described in
section:
• Refitting the SMB unit on page 242

4 Repair
Continued
Action Note
8 Refit the cables with the screen connec-
tions.
A
xx0900000035
Parts:
• A: Screen connections (4 pcs)
9
Tip
When refitting connectors on the bracket,

put it at a 90° angle.
xx0900000013
Parts:
• A: Bracket
• B: Base
10 Before refitting the connectors on the
bracket, arrange cables and connectors as
shown in the figure.
A B C
xx1200000857
A R1.CP/CS
B R1.MP
C Air hose

4 Repair
Continued
Action Note
11 Refit the connectors and air hose on the
bracket:
• R1.CP/CS
• R1.MP
Tip
Do not refit the R1.SMB-connector and air

hose at this stage. It will be easier to refit
these two when the bracket has been fitted
to the distance screws.
xx0900000017
Connectors:
• A: Earth cables
• B: R1.SMB1-2
• C: R1.SMB3-6
• D: R2.SMB
• E: R1.CP/CS
• F: R1.MP
• G: Air hose
• H: Position of R1.CBUS (if used)
• J: R1.SMB
12 Secure the bracket on the distance screws.
B
C
D
xx1200000887
A Base
B Distance screw
C Attachment screw
D Bracket
13 Reconnect connectors on the brake release
unit:
• X8
• X9
• X10

4 Repair
Continued
Action Note
14 Refit the R1.SMB-connector on the bracket.
Tip
Use a deep well hexagon socket, width 30

mm (like the ones used for spark plugs, or
similar). A
xx1200000888
D
C
B
xx1200000889
A Thin nut, width 30 mm

B R1.SMB
C Bracket
D Air connector
15 Refit the air hose connector on the bracket.
Note
Check that there is no leakage from the air

hose.
16 Reconnect the battery cable.

17 Secure the battery cable with cable straps.
xx0900000099
Parts:
• A: Cable straps (2 pcs)

4 Repair
Continued
Action Note
18 Use caution when pushing the base cover
into position while at the same time check-
ing that no cables are damaged.
C
xx0800000456
Parts:
• A: Base
• B: Base cover
• C: Attachment screws (6 pcs)
19 Secure the base cover with its attachment
screws.
20 Refit the bracket on the frame. See the figure in:
• Location of the cable harness on
page 223
21 Refit the cable straps securing the cable See the figure in:
harness to the frame. • Location of the cable harness on
page 223
22 Continue the refitting of the cable package How to refit the cable harness on the
on lower arm and armhouse. lower arm and armhouse is described in
section:
lower arm and armhouse on
page 234
Refitting the cable harness in the lower arm and armhouse

Use this procedure to refit the cable harness in the lower arm and armhouse.
Tip
Before starting this procedure, first refit the cable harness in the frame and base.
See:

4 Repair
Continued
Action Note
1
DANGER
Turn off all:

working area.
2 Secure the brackets on the lower arm.
D
C
xx0900000020
Parts:
• A: Bracket, lower arm
• B: Bracket, lower arm
• D: Cable bracket
3 Refit the cable straps securing the cable See the figure in:
harness to the lower arm. • Location of the cable harness on
page 223 (Cable harness, lower arm)
4 Push the cable harness carefully into the
armhouse.

4 Repair
Continued
Action Note
5 Secure the bracket, armhouse with its at-
tachment screws.
xx0800000335
Parts:
6 Secure the bracket to the armhouse with
its attachment screws.
xx0800000338
Parts:
• A: Signal lamp
• B: Bracket, armhouse
• C: Cable bracket
7 Reconnect the axis-3, axis-4, axis-5 and How to connect the axis-3, axis-4, axis-5
axis-6 motor cables. and axis-6 motor cables, see:
8 Recalibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 353.
General calibration information is included
in section Calibration on page 341.

4 Repair
Continued
Action Note
9
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.
10
DANGER
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 53.

4 Repair
4.3.3 Replacing SMB unit
Location of SMB unit

The SMB unit (SMB = Serial measurement board) is located in the base below the
brake release unit, as shown in the figure.
xx0800000466
A R1.SMB3-6
B R1.SMB1-2
C R2.SMB
D SMB unit
E Attachment screws M6x16 quality 8.8-A2F (2 pcs)
F Brake release unit
G Bracket
Required equipment
Note
There are different variants of SMB units and batteries. The variant with the
3-pole battery contact (RMU) has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!
Equipment Note
on page 385.

4 Repair
Continued
Equipment Note
SMB unit For spare part no. see chapter Spare parts,
section:

Action Note
calibration:
Removing the SMB unit

Use this procedure to remove the SMB unit.
Action Note
2
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
3 Remove the base cover.
CAUTION
C
Clean cover from metal residues before
opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail-
ures.
A
xx0900000103
Parts:
A Attachment screws (6 pcs)
B Base cover
C Cable straps, securing the battery
cable (2 pcs)
4 Cut the cable straps securing the battery
cable.
5 Remove the screw that secures the bracket
and unscrew the three other screws a little
just enough to be able to slide the bracket
sideways.
Note
It is not needed to remove these three

screws.
xx0900000100
Parts:
A Screw to be removed
B Screws to be unscrewed a little (3
pcs)

4 Repair
Continued
Action Note
6 Remove the bracket by sliding it off the re- Cable harness can stay connected to all
maining three attachment screws and put connectors except to the SMB unit.
it at a 90° angle from the base.
Putting the bracket at a 90° angle facilitates
the disconnecting of cables from the
bracket.
Note
Use caution when performing this procedure xx0900000013

order not to damage cables or other com-
ponents! Parts:
A Bracket at a 90° angle
B Base
7 Disconnect cable clamps.
A
xx0900000035
Parts:
A Cable clamps
8 Unscrew the attachment screws securing See the figure in:
the SMB unit just enough to be able to re- • Location of SMB unit on page 238
move the SMB unit.
9 Remove the SMB unit.
10 Disconnect the battery cable by pressing
down the upper lip of the R1.G connector
to release the lock while pulling the connect-
or upwards.
xx1700000993
11 Disconnect the remaining connectors on See the figure in:

the SMB unit: • Location of SMB unit on page 238
• R1.SMB1-2
• R1.SMB3-6
• R2.SMB

4 Repair
Continued
Refitting the SMB unit

Use this procedure to refit the SMB unit.
Action Note
1
DANGER
Turn off all:

working area.
2 Reconnect contacts on the SMB unit:

• R1.SMB1-2
• R1.SMB3-6
• R2.SMB
• Battery cable R1.G (X3) Make sure
the lock snaps into place during refit-
ting.
xx1700000994
3 Place the SMB unit on its attachment See the figure in:
screws. • Location of SMB unit on page 238
4 Secure the SMB unit with its attachment
screws.
5 Refit the cable clamps.
A
xx0900000035
Parts:
A Cable clamps
6 Put back the cable harness in the base and See the figure in:
refit the bracket on the distance screws. • Location of SMB unit on page 238
Note

order not to damage cables or other com-
ponents!

4 Repair
Continued
Action Note
7 Secure the battery cable with cable straps.
into position while at the same time check-
ing that no cables are damaged.
9 Secure the base cover with the attachment
screws.
C
xx0800000456
Parts:
A Attachment screws (6 pcs)
B Base cover
C Base
11
DANGER

on page 53.

4 Repair
4.3.4 Replacing the brake release board
Location of brake release board

The brake release board is located as shown in the figure.
xx0900000101
A Brake release board
Connectors on push-button board

The connectors X8, X9 and X10 are placed on the push-button board as shown in
the figure below.
xx1700000978

4 Repair
Continued
Required equipment
Equipment Note
DSQC 563 Brake release 3HAC16035-1
board
Other tools and procedures These procedures include refer-
may be required. See references to the tools required.
tions below.
Removing the brake release board

Use this procedure to remove the brake release board.
Action Note
1
DANGER
Turn off all:

working area.
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling

the unit read the safety information in sec-
tion WARNING - The unit is sensitive to
ESD! on page 57
3 Remove the push button guard from the The guard must be removed to ensure a
SMB cover. correct refitting of the brake release
board.

4 Repair
Continued
Action Note
4 Remove the base cover.
CAUTION
Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous fail- A
ures.
C
xx0800000456
Parts:
A Base
B Base cover
C Attachment screws M6x16 quality
8.8-A2F (6 pcs)
5 Take a picture or make notes of how the
robot cabling is positioned in regard to the
brake release board.
6 Disconnect connectors X8, X9 and X10 from
the brake release board.
xx1700000978
7 Remove the nuts securing the brake release

board.
8 Remove the brake release board.
Refitting the brake release board

Use this procedure to refit the brake release board.
Action Note
1
DANGER
Turn off all:

area.

4 Repair
Continued
Action Note
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling

the unit read the safety information in section
WARNING - The unit is sensitive to ESD! on
page 57
3 Secure the brake release board to the bracket Maximum tightening torque: 5 Nm.
with its nuts with flange. See the figure in:
• Location of brake release board
on page 244
4 Reconnect connectors X8, X9 and X10 to the
brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms
are snapped down properly.
xx1700000978
5 Verify that the robot cabling is positioned

correctly, according to previously taken pic-
ture/notes.
WARNING
Screened cables must not get in contact with

the brake release board after installation.
Eliminate all risks of contact between
screened cables and the brake release board.

into position while at the same time checking
that no cables are damaged.
C
xx0800000456
Parts:
A Base
B Base cover
C Attachment screws M6x16 quality
8.8-A2F (6 pcs)
7 Secure the base cover with its attachment
screws.

4 Repair
Continued
Action Note
8
WARNING
Before continuing any service work, follow

the safety procedure in section WARNING -
The brake release buttons may be jammed
after service work on page 54!
9 Refit the push button guard to the SMB cover.

10 Press the push buttons 1 to 6, one at a time,
to make sure that the buttons are moving
freely and do not stay in any locked position.
11
DANGER

when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on
page 53.

4 Repair
4.3.5 Replacing the base
Location of base and complete arm system

The complete arm system is defined as:
• complete upper arm (includes: wrist unit, tubular shaft unit and armhouse)
• lower arm
• frame.
The location of the base and the complete arm system is shown in the figure.
xx0800000345
A Base
B Frame
C Lower arm
D Armhouse (part of Upper arm complete)
E Tubular shaft unit (part of Upper arm complete)
F Wrist unit (part of Upper arm complete)

4 Repair
Continued
Position of robot when replacing base from complete arm system

During the removal and refitting of the base from the complete arm system, the
following method is recommended. How to perform the method is detailed in the
procedures below. The position of the robot on loading pallets is shown in the
figure.
B
xx0800000352
A Loading pallets
B Robot
Required equipment
Equipment Note
Roundslings 3 pcs. Lengths: 2 m (2 pcs), 1.5 m (1 pc).
Lifting capacity: 1 000 kg.
Crowbar Small
Guide pins
on page 385.
Loctite 7063 For cleaning.
Loctite 574 For sealing.

4 Repair
Continued

Action Note
calibration:
Removing the base

Use this procedure to remove the base from the arm system.
Action Note
figure.
xx0800000336

4 Repair
Continued
Action Note
3
DANGER
Turn off all:

working area.
4 Drain the axis-1 gearbox. How to drain oil is detailed in section

Note on floor mounted robots on
page 162
Elapsed time varies depending on the tem-
perature of the oil.
5 Remove the cable harness in the base, the How to remove the cable harness in base
frame and the lower arm of the robot. and frame is detailed in sections:
• Removing cable harness in base
on page 212
Tip
on page 218
Wrap up the cabling against the frame to
keep it undamaged during the remaining • Removing cable harness in lower
work. arm and armhouse on page 219
6 Secure the robot with roundslings in an Dimensions are specified in Required

overhead crane. equipment on page 250.
C
B
xx1100000582
A Roundsling 1.5 m
B Roundsling 2 m
C Roundsling 2 m

4 Repair
Continued
Action Note
7
CAUTION

accordingly!
8 See the figure in:

Tip • Position of robot when replacing
base from complete arm system on
page 250
Put the robot on its side on a couple of
loading pallets put on top of each other in
order to create a more comfortable working
situation.
9
DANGER
Do not remove either motor axis 2 or 3 at

this stage!
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.
10 Remove the bolts securing the robot to the See the figure in:
foundation and carefully put it on the load- • Position of robot when replacing
ing pallets as shown in the figure. base from complete arm system on
page 250
WARNING
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.

4 Repair
Continued
Action Note
11 Remove the cover plate at the bottom of the Other design than Type C:
base.
xx0800000357
Type C:
xx1200000634
Parts:
• A: Gearbox axis 1
• B: Base
• C: Other design than Type C: At-
tachment screws M8x40 quality
Steel 12.9 Gleitmo and washers
(24+24 pcs)
• C: Type C: Attachment screws
M12x50 quality Steel 12.9 Gleitmo
and washers (24+24 pcs)
• D: O-ring (Not visible behind cover
plate in figure of Type C)
• E: Cover plate
• F: Attachment screws M6x16 qual-
ity 8.8-A2F (5 pcs)
12
CAUTION
The robot base weighs 60 kg.

accordingly!
13 Secure the base of the robot with round-

slings in an overhead crane or similar.

4 Repair
Continued
Action Note
14 Remove the attachment screws that secure Shown in previous figure.
the base to the axis 1 gearbox.
Note
The attachment screws on Type C are dif-

ferent from the ones on Other design than
type C!
15 Remove the base carefully.
Tip
A small crowbar will probably be needed to

carefully remove the base.
xx1200000891
Refitting the base

Use this procedure to refit the base to the complete arm system.
Action Note
1
DANGER
Turn off all:

working area.
2 Remove residues of old Loctite and other

contaminations from surfaces before apply- Tip
ing new Loctite 574.
Use Loctite 7063 (or similar) for cleaning.

4 Repair
Continued
Action Note
3 Apply Loctite 574 around the screwholes
on gearbox axis 1 as shown in the figure.
xx0800000353
Parts
• A: Loctite 574
• B: Screwhole in gearbox axis 1
• C: Gearbox axis 1
4
CAUTION
The robot base weighs 60 kg.

accordingly!
5 Secure the base with a roundsling in an

overhead crane or similar and lift it to the
mounting site.
6 Apply guide pins in opposite holes in the
axis-1 gearbox.

4 Repair
Continued
Action Note
7 Refit the base with its attachment screws Other design than Type C:
and washers. Tightening torque: 35 Nm.
Note
The attachment screws on Type C are dif-

ferent from the ones on Other design than
Type C!
xx0800000357
Type C:
Tightening torque: 110 Nm.
xx1200000634
Parts:
• B: Base
• C: Other design than Type C: At-
tachment screws M8x40 quality
Steel 12.9 Gleitmo and washers
(24+24 pcs)
• C: Type C: Attachment screws
M12x50 quality Steel 12.9 Gleitmo
and washers (24+24 pcs)
• D: O-ring (Not visible behind cover
plate in figure of Type C)
• E: Cover plate
• F: Attachment screws M6x16 qual-
ity 8.8-A2F (5 pcs)
8 Apply some grease to the o-ring and refit
the o-ring between the cover and base.
9 Refit the cover plate at the bottom of the
base with its attachment screws.

4 Repair
Continued
Action Note
10
CAUTION

accordingly!
11 Lift the robot from the loading pallets, using

caution and refit it to the foundation.
13
DANGER

on page 53.

4 Repair
4.4.1 Replacing the complete upper arm
4.4 Upper arm
Location of the complete upper arm

Type C
The upper complete arm is located as shown in the figure.
xx1200000635
A Upper arm
B Lower arm
C Washer (3 pcs)
xx1200000520
D Attachment screws M10x40 quality steel 12.9 Gleitmo (15 pcs)

E Axis-3 gearbox

4 Repair
Continued

The complete upper arm is located as shown in the figure.
xx0800000337
A Upper arm
B Lower arm
C Attachment screws M8x40 quality steel 12.9 Gleitmo (19 pcs)
D Washers quality steel 8.4x13x1.5 (19 pcs)
E Axis-2 gearbox
Required equipment
Equipment Note
Armhouse For spare parts no. see Spare parts - Upper arm
(2.05/2.50/2.55) in Product manual, spare
parts - IRB 2600.
Tubular shaft unit For spare parts no. see Spare parts - Upper arm
parts - IRB 2600.

4 Repair
Continued
Equipment Note
Rotating lifting point 2 pcs. Dimension: M8.
Example: Gunnebo RLP GrabiQ M8-10.
xx1100000564
Washer Required if the screw in the rotating lifting point

bottoms.
Inner diameter: 12 mm. Outer diameter: min. 23
mm. Thickness: enough to prevent the screw in
the rotating lifting point to bottom.
Roundslings 3 pcs.
Length: 1.5 m.
Lifting capacity: 500 kg.
Screws 2 pcs. Used to prevent the roundsling at the wrist
from sliding.
Dimension:
• M6. Length: 70 mm. Quality: 8.8. (IRB
4600 - 20/2.5)
• M8. Length: 70 mm. Quality: 8.8. (IRB
4600 - 60/2.05, - 45/2.05, - 40/2.55)
Guide pins Type C: M10 (2 pcs)
Other design than Type C: M8 (2 pcs)
page 385.
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.

Action Note

4 Repair
Continued
Action Note
calibration:
Removing the complete upper arm

Use this procedure to remove the complete upper arm. This procedure can be
done without draining the axis 3 gearbox.
Action Note
2 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
3
DANGER
Turn off all:

working area.
4
CAUTION
The robot upper arm weighs 140 kg.

accordingly!
5 Attach the lifting accessories to the upper See Attaching the lifting accessories to
arm. the upper arm on page 264.

4 Repair
Continued
Action Note
6 Unload the weight of the upper arm by
stretching the roundslings.
Tip
Turn on the power temporarily and release

the brakes of axis 3 to rest the weight onto
the roundslings.
7
DANGER
Turn off all:

working area.
8 Disconnect all motor cables from motors How to disconnect cables from motors is
axes 3, 4, 5 and 6. detailed in sections:
9 Remove the bracket fitted on the tubular
shaft unit.
xx0800000335
Parts:
• B: Attachment screws M6x16 qual-
ity 8.8-A2F (2 pcs)
• C: Bracket
10 Remove the signal lamp, if used.

4 Repair
Continued
Action Note
11 Remove the cable bracket on the armhouse.
xx0800000338
Parts:
• A: Signal lamp
• B: Bracket
12 Using caution, pull the cable package out
of the hole where the cable bracket was fit-
ted.
13 Remove the attachment screws securing See the figure in:
the upper arm to the lower arm. • Location of the complete upper arm
on page 259
Note
Do not remove the attachment screws

securing the gearbox axis 3 to the arm-
house!
14 Remove the complete upper arm.
Attaching the lifting accessories to the upper arm

Attaching the lifting accessories
Action Note
1 Fit two screws in the wrist unit. Dimension is specified in Required equipment on
The purpose of these screws is page 260.
to prevent the roundsling from
sliding.
xx1100000568

4 Repair
Continued
Action Note
2 Fit two rotating lifting points to the Dimension is specified in Required equipment on
attachment holes in the arm page 260.
house, see the figure. Secure the
lifting point tightly against the arm
house, but at the same time mak-
ing sure that the screw does not
bottom. Use an extra washer if
the screw does bottom.
xx1100000565
xx1100000566
3 Run a roundsling through each Dimension is specified in Required equipment on

rotating lifting point and fasten page 260.
both ends at the lifting hook. See figure Attaching the roundslings to the upper
arm on page 266.
4 Make a loop of the third round- Dimension is specified in Required equipment on
sling, running it around the wrist page 260.
unit. Run the roundsling on both See figure Attaching the roundslings to the upper
sides of the screws and fasten the arm on page 266.
free end of the roundsling to the
lifting hook.

4 Repair
Continued
Attaching the roundslings to the upper arm
xx1100000567
A Screws to prevent the roundsling from sliding, 2 pcs

B Rotating lifting point, 2 pcs
C Roundsling around wrist unit
Length: 1.5 m.
D Roundsling attached to arm house, 2 pcs
Length: 1.5 m.
Refitting the complete upper arm

Use this procedure to refit the complete upper arm.
Action Note
1
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
2
CAUTION

accordingly!
3 Clean all assembly surfaces.

arm. the upper arm on page 264.
5 Fit guide pins to the upper arm. Specified in Required equipment on
page 260.
6 Lift the upper arm to the robot using an
overhead crane.
7 Release the brakes of the axis 3 motor.
8 Refit the upper arm to the lower arm with See the figure in:
its attachment screws. • Location of the complete upper arm
on page 259
Note Tightening torque Other design than
Type C:
Use new attachment screws! • 35 Nm
It may be necessary to turn the gear by ro- Tightening torque and angle Type C:
tating the motor pinion with a rotation tool, • 50 Nm and 90° angle
motor beneath the motor cover.
9 Using caution, push the cable package
through the hole where the cable bracket
will be fitted.
xx0800000338
Parts:
• A: Signal lamp
• B: Bracket
10 Refit the cable bracket with its attachment
screws.
11 Reconnect all motor cables. How to connect motor cables is detailed
in sections:

4 Repair
Continued
Action Note
12 Refit the bracket on the tubular shaft unit.
xx0800000335
Parts:
ity 8.8-A2F (2 pcs)
• C: Bracket
13 Refit the signal lamp, if used.
15
DANGER

on page 53.

4 Repair
4.4.2 Replacing complete tubular shaft unit
Location of tubular shaft unit

The tubular shaft unit is located as shown in the figure.
xx0800000334
A Armhouse
B Parallel pin, hardened 8x16 m6 (2 pcs)
C Attachment screws M8x35 quality 8.8-A2F and washers (10 + 10 pcs)
D Tubular shaft unit
E Wrist unit
Required equipment
Equipment Note
Tubular shaft unit For spare parts no. see Spare parts - Upper arm
parts - IRB 2600.
Guide pins 2 pcs. Dimension: M8.
Cleaning agent Isopropanol
Sealing liquid Loctite 574
page 385.
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.

4 Repair
Continued

Action Note
calibration:
Removing complete tubular shaft unit

Use this procedure to remove the complete tubular shaft unit.
Action Note
2 Drain oil from gearbox axis 4. How to drain the oil from the gearbox is
described in section:
on page 185
figure.
xx0800000336

4 Repair
Continued
Action Note
4
DANGER
Turn off all:

working area.
5 Remove the bracket securing the cable

package to the tubular shaft unit by remov-
ing its attachment screws.
xx0800000335
Parts:
ity 8.8-A2F (2 pcs)
• C: Bracket
6 Place the cable package in a way that it will
not be damaged in the continued removal
procedure.
7 Remove motors axes 4, 5 and 6. How to remove motors is described in
section:
8 How to remove the wrist unit is detailed
Tip in section:
• Removal of wrist unit on page 277
If only the tubular shaft unit shall be re-
placed, it is a good idea to remove the wrist
unit at this stage.
9
CAUTION
The robot arm tube weighs 65 kg.

accordingly!

4 Repair
Continued
Action Note
10 Secure the tubular shaft unit with round-
slings in an overhead crane.
CAUTION
Prevent the slings from sliding!

For example a small plate can be fitted to
the lower attachment hole for the cable
bracket (removed in a previous step). The
plate should be fitted so it points down-
wards and functions as a mechanical stop
for the roundsling.
At the other end of the tubular shaft unit, a
shackle can be fitted if the wrist unit is re-
moved.
11 Remove the attachment screws that secure See the figure in:
the tubular shaft unit. • Location of tubular shaft unit on
page 269
12 Remove the tubular shaft unit using caution.
The tubular shaft unit is fitted with Loctite. Note
There are two parallel pins guiding the

CAUTION
tubular shaft unit into its place. See figure
in Replacing complete tubular shaft unit
Do not damage the gears when removing on page 269.
the tubular shaft unit.
CAUTION
Remaining oil will drain out from the gear-

box cavity when the tubular shaft is lifted
out.
Refitting complete tubular shaft unit

Use this procedure to refit the tubular shaft unit.
Action Note
1
DANGER
Turn off all:

working area.
2 Remove residues of old Loctite and other

contaminations from the assembly surfaces.
Remove any painting from the assembly
surfaces, with a knife.

4 Repair
Continued
Action Note
3 Apply sealing liquid (Loctite 574) on the A
surface between the tubular shaft unit and
the armhouse. B C
Make sure to apply the sealing liquid in
circles around each of the attachment holes.
xx0800000457
Parts:
A Armhouse
B Surface where Loctite 574 shall be
applied
C Tubular shaft unit
D Cylindrical pin (2 pcs)
4
CAUTION
The robot arm tube weighs 65 kg.

accordingly!
5 Secure the tubular shaft unit with a round-

sling in an overhead crane.
CAUTION
Prevent the slings from sliding!

For example a small plate can be fitted to
the lower attachment hole for the cable
bracket (removed in a previous step). The
plate should be fitted so it points down-
wards and functions as a mechanical stop
for the roundsling.
At the other end of the tubular shaft unit, a
shackle can be fitted if the wrist unit is re-
moved.
6 Fit guide pins in the upper arm house. Specified in Required equipment on
page 269.
7 Refit the tubular shaft unit, using caution.
Note
CAUTION
There are two parallel pins guiding the
Do not damage the gears when refitting the tubular shaft unit into its place.
tubular shaft unit.

4 Repair
Continued
Action Note
8 Secure the tubular shaft unit with its attach- See the figure in:
ment screws. • Location of tubular shaft unit on
page 269
Tightening torque: 22 Nm
9 Refit motors axes 4, 5 and 6. How to refit motors is described in sec-
tion:
10 Perform a leak-down test. See Performing a leak-down test on
page 204.
11 Refit the bracket securing the cable package
to the tubular shaft unit, with its attachment
screws.
xx0800000335
Parts:
ity 8.8-A2F (2 pcs)
• C: Bracket
12 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 278
13 Refill gearbox axis 4 with oil. How to refill oil in gearbox is described in
section:
on page 185
15
DANGER

on page 53.

4 Repair
4.4.3 Replacing wrist unit
Location of wrist unit

The wrist unit is located in the upper arm as shown in the figures.
IRB 4600 -60/2.05, -45/2.05, -40/2.55
B
C
E
F
xx0800000333
A Upper arm
B Gear
C O-ring sealing plate
D Wrist unit
E Spring washer, conical 8.4x18x2, quality steel-mZn12c (7 pcs)
F Attachment screw M8x40, quality steel 12.9 Gleitmo (7 pcs)
G Guide pin
(only available for robots that are calibrated with Axis Calibration)

4 Repair
Continued
IRB 4600 -20/2.50
B
C
D
G
E
xx0800000341
A Upper arm
B Attachment screw M8x40, quality steel 12.9 Gleitmo (5 pcs)
C Spring washer, conical 8.4x18x2, quality steel-mZn12c (5 pcs)
D Gears
E Wrist unit
F O-ring (Placed on the wrist. Not visible here)
G Guide pin
(only available for robots that are calibrated with Axis Calibration)
Required equipment
Equipment Note
Wrist unit For spare parts no. see Spare parts - Upper
arm (2.05/2.50/2.55) in Product manual, spare
parts - IRB 2600.
O-ring For spare parts no. see Spare parts - Upper
arm (2.05/2.50/2.55) in Product manual, spare
parts - IRB 2600.
Measuring tool For adjusting the play.
on page 385.

4 Repair
Continued

Action Note
calibration:
Removal of wrist unit

Use this procedure to remove the wrist unit.
Action Note
take actions accordingly prior to beginning the
repair procedure.
2
DANGER
Turn off all:

area.
3 Drain oil from gearbox axes 5-6. How to drain the oil from gearbox axes
5-6 is described in section:
• Changing oil, axes-5 and -6
gearboxes on page 189

4 Repair
Continued
Action Note
4
CAUTION
The robot wrist unit weighs 25 kg (IRB 4600 -

60/2.05, - 45/2.05, -40/2.55) and 15 kg (IRB 4600
- 20/2.50).
cordingly!
5 Secure the wrist unit with a roundsling in an

overhead crane or similar.
6 Remove the attachment screws and carefully See the figure in:
remove the wrist unit. • Location of wrist unit on
page 275
CAUTION
Do not damage gears!
Refitting of wrist unit

Use this procedure to refit the wrist unit.
Action Note
1
DANGER
Turn off all:

area.
2 Check if there is a parallel pin hole in the upper

arm tube.
The hole is available on robots that are calib-
rated with the Axis Calibration method.
xx1600000690

4 Repair
Continued
Action Note
3 If there is a hole, fit the parallel pin into the
corresponding hole in the wrist (enclosed with
the new wrist spare part).
Note
If the parallel pin is not installed on a robot cal-

ibrated with Axis Calibration, the calibration
result will be affected negatively.
xx1600000689
Verify that the parallel pin sticks out

from the wrist according to the meas-
urement given below.
IRB 4600 -60/2.05, -45/2.05, -40/2.55
6 ±0,5
xx1600000702
IRB 4600 -20/2.50
0
4 -0,5
xx1600000703

Remove any painting from the assembly sur-
faces, with a knife.

4 Repair
Continued
Action Note
5 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 275
6 Check the o-ring. Replace if damaged. See the figure in:
• Location of wrist unit on
7 Prepare the refitting of the wrist by inserting the page 275
attachment screws and washers in the upper
arm tube.
8
CAUTION
The robot wrist unit weighs 25 kg (IRB 4600 -

60/2.05, - 45/2.05, -40/2.55) and 15 kg (IRB 4600
- 20/2.50).
cordingly!
9 Carefully put the wrist unit in its place on the

upper arm.
CAUTION
Do not damage gears!
CAUTION
Make sure that the o-ring stays in place on the

wrist unit!
10 Adjust the play of the wrist by following these

steps:
• Fit the measuring tool at the rear of the
motor.
• Push the wrist as shown in the figure to
locate the smallest play in the same way
as for adjustment of motors for axes 4,
5 and 6. See Refitting motors on page 306.
xx1000000223
Parts:
• A: Gears on drive shaft unit,
axes 5-6
• B: Gears on the wrist
11 Secure the wrist unit with its attachment screws See the figure in
and washers. • Location of wrist unit on
page 275
12 Measure the play by moving axes 5 and 6 with How to measure the play is described
the measuring tool. in sections:
• Measuring the play, axis 5 on
page 282
• Measuring the play, axis 6 on
page 285

4 Repair
Continued
Action Note
page 204.
14 Refill oil in gearbox axes 5-6. How to fill oil in gearbox axes 5-6 is
• Changing oil, axes-5 and -6
gearboxes on page 189
15 Recalibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum, enclosed with the calibration
tools.
Axis Calibration is described in Calib-
rating with Axis Calibration method on
page 353.
General calibration information is in-
cluded in section Calibration on
page 341.
16
DANGER
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 53.

4 Repair
4.4.4 Measuring the play, axis 5
General
After reassembly due to repair work or any other reason, the play in axis 5 and 6
must be checked to ensure the repetition accuracy of the robot positioning. The
procedure for axis 5 is detailed below.
Required equipment
Equipment, etc. Art. no. Note

Standard toolkit - Content is defined in sec-
tion Standard tools on
page 385.
Measuring tool, play 3HAB1611-6
(IRB 4600 -60/2.05, -45/2.05, -40/2.55)
(IRB 4600 -20/2.50)
Other tools and procedures may be required. These procedures include
See references to these procedures in the references to the tools re-
step-by-step instructions below. quired.
Measurement, axis 5
The procedure below details how to measure the play of axis 5.
Note
The measuring tool and measuring values differ depending on robot version!
Action Information
1
DANGER
Turn off all:

working area.
2 Move the robot to calibration position and

turn the axis 4 90°.
3 Fit the measuring tool, play to the turning Art. no. is specified in Required equip-
disk. ment on page 282.

4 Repair
Continued
Action Information
4 Apply load F in one direction, as shown in
the figure to the right.
Note
Different load and distances for the differ-

ent robot versions, as specified to the right!
xx0300000186
Values for IRB 4600 - 60/2.05, -45/2.05,

-40/2.55:
• A: Measuring tool, play
• B: 100 mm
• C: 135 mm
• F: 90N
Values for IRB 4600 -20/2.50:
• B: 140 mm
• C: 85 mm
• F: 40N
5 Remove the load and set the dial indicator
to zero.
6 Apply load F in the opposite direction, as
shown in the figure to the right.
xx0300000187
Values for IRB 4600 -60/2.05, -45/2.05,

-40/2.55:
• B: 135 mm
• C: 100 mm
• F: 90N
Values for IRB 4600 -20/2.50:
• B: 140 mm
• C: 85 mm
• F: 40N

4 Repair
Continued
Action Information
7 Remove the load and measure the play by The maximum play allowed at the given
reading the dial indicator. distance from the center of axis 5 is, for
robot version:
• IRB 4600 -60/2.05, -45/2.05, -
40/2.55: 0.15 mm
• IRB 4600 -20/2.50: 0.12 mm

4 Repair
General
After reassembly due to repair work or any other reason, the play in axis 5 and 6
must be checked to ensure the repetition accuracy of the robot positioning. The
procedure for axis 6 is detailed below.
Required equipment

Standard toolkit - Content is defined in sec-
tion Standard tools on
page 385.
(IRB 4600 -60/2.05, -45/2.05, -40/2.55)
(IRB 4600 -20/2.50)
Other tools and procedures may be required. These procedures include
See references to these procedures in the references to the tools re-
step-by-step instructions below. quired.
Measurement, axis 6
The procedure below details how to measure the play in axis 6.
Note
The measuring tool and measuring values differ depending on robot version!
Action Information
1
DANGER
Turn off all:

working area.
2 Fit the measuring tool, play to the turning Art. no. is specified in Required equipment
disk. on page 285.

4 Repair
Continued
Action Information
3 Attach a weight (m) at a distance (B) from
the wrist flange, in order to avoid the ef-
fects of play on axis 5.
Note
Different weight and distance for the dif-

ferent robot versions, as specified to the
right!
xx0300000188
Values for robot versions IRB 4600 -

60/2.05, -45/2.05, -40/2.55:
• B: 100 mm
• m: 20 kg
Values for robot version IRB 4600 -20/2.50:
• B: 140 mm
• m: 10 kg
4 Apply load F in one direction.
Note
Different load and distances for the differ-

ent robot versions, as specified to the
right!
xx0300000189

60/2.05, -45/2.05, -40/2.55:
• B: 100 mm
• C: 100 mm
• F: 50N
• A: Mearuring tool, play
• B: 100 mm
• C: 150 mm
• F: 40N
5 Remove the load and set the dial indicat-
or to zero.

4 Repair
Continued
Action Information
6 Apply load F in the opposite direction,
as shown in the figure to the right.
xx0300000190

60/2.05, -45/2.05, -40/2.55:
• B: 100 mm
• C: 150 mm
• F: 50N
• B: 100 mm
• C: 150 mm
• F: 40N
7 Remove the load and measure the play The maximum play allowed at the given
by reading the dial indicator. distance (B) from the center of axis 6 is, for
robot version:
• IRB 4600 -60/2.05, -45/2.05, -40/2.55:
0.16 mm
• Values for IRB 4600 -20/2.55: 0.22
mm

4 Repair
4.5.1 Replacing the lower arm
4.5 Lower arm
Location of lower arm

Type C
The lower arm is located as shown in the figure.
xx1200000636
A Upper arm
B Axis-3 gearbox

4 Repair
Continued
C Washer with five holes (3 pcs)
xx1200000520
D Attachment screws M10x40 quality Steel 12.9 Gleitmo (15 pcs)

E Lower arm
F Frame
G Axis-2 gearbox
H Washer (18 pcs)
J Attachment screws M12x50 quality Steel 12.9 Gleitmo (18 pcs)

The lower arm is located as shown in the figure.
B C D E
G
H J
xx0800000360
A Upper arm
B Axis-3 gearbox
C Lower arm

4 Repair
Continued
D Washer (19 pcs)

E Attachment screws M8x40 quality Steel 12.9 Gleitmo (19 pcs)
F Frame
G Axis-2 gearbox
H Washer (18 pcs)
J Attachment screws M12x50 quality Steel 12.9 Gleitmo (18 pcs)
Required equipment
Equipment Note
Lower arm For spare parts no. see Spare parts - Lower
arm and motors in Product manual, spare
parts - IRB 2600.
on page 385.

Action Note
calibration:

4 Repair
Continued
Removing the lower arm

Use this procedure to remove the lower arm.
Action Note
figure.
xx0800000336
3
DANGER
Turn off all:

working area.
4 Remove the cable package from all axes How to remove the cable package in
except in the base. frame, lower arm and armhouse is de-
scribed in sections:
on page 218
• Removing cable harness in lower
arm and armhouse on page 219
5 Secure the upper arm with a roundsling in
an overhead crane.
6 Remove the complete upper arm and put it How to remove the complete upper arm
on a loading pallet. is described in section:
• Removing the complete upper arm
on page 262
7
CAUTION
The robot lower arm weighs 65 kg.

accordingly!

4 Repair
Continued
Action Note
8 Fit a lifting lug in one of the upper holes in The figure shows other design than Type
the lower arm, for the attachment screws. C, but the principle of fitting the lifting lug
is the same on Type C.
xx0800000379
Parts:
• A: Lifting lug
9 Remove the attachment screws securing A
the lower arm to gearbox axis 2.
B C D E
xx0800000377
Parts:
• A: Frame
• B: Gearbox axis 2
• C: Lower arm
• D: Washer (17 pcs)
• E: Attachment screws M12x50
quality steel Gleitmo 12.9 (17 pcs)
10 Remove the lower arm.

4 Repair
Continued
Refitting the lower arm

Use this procedure to refit the lower arm.
Action Note
1
DANGER
Turn off all:

working area.
2
CAUTION
The robot lower arm weighs 65 kg.

accordingly!
3 Fit a lifting lug in one of the upper holes in The figure shows other design than Type
the lower arm, for the attachment screws. C, but the principle of fitting the lifting lug
is the same on Type C.
xx0800000379
Parts:
• A: Lifting lug
4 Secure the lower arm with a roundsling in
an overhead crane and lift it to the robot.

4 Repair
Continued
Action Note
5 Refit the attachment screws securing the A
lower arm to gearbox axis 2.
B C D E
xx0800000377
Tightening torque:
• 110 Nm
Parts:
• A: Frame
• C: Lower arm
quality steel Gleitmo 12.9 (17 pcs)
6 Secure the complete upper arm with round-
slings in an overhead crane and lift it to the
robot.
7 Refit the complete upper arm. How to refit the complete upper arm is
• Refitting the complete upper arm
on page 266
8 Refit the cable package. How to refit the cable package in frame,
lower arm and armhouse is described in
sections:
frame on page 225
page 234
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 353.
10
DANGER

on page 53.

4 Repair
4.6.1 Replacing stop pin axis 1
4.6 Frame and base
Location of stop pin axis 1

The stop pin axis 1 is located as shown in the figure.
xx0800000045
A Attachment screws M6x16 quality 8.8-A2F (2 pcs)

B Bracket
C O-ring (2 pcs)
D Bracket
E Stop pin
Required equipment
Equipment Note
Stop pin For spare parts no. see Spare parts - Frame
and base in Product manual, spare parts - IRB
2600.
page 385.

4 Repair
Continued
Equipment Note
Removing the stop pin, axis 1

Use this procedure to remove the stop pin axis 1.
Action Note
1
DANGER
Turn off all:

working area.
2 Remove the attachment screws securing See the figure in

the bracket and stop pin. • Location of stop pin axis 1 on
page 295
3 Remove the bracket and stop pin. See the figure in
• Location of stop pin axis 1 on
page 295
Refitting the stop pin, axis 1

Use this procedure to refit the stop pin axis 1.
Action Note
1
DANGER
Turn off all:

working area.
2 Fit the two o-rings on the stop pin. See the figure in
• Location of stop pin axis 1 on
page 295

4 Repair
Continued
Action Note
3 Fit the stop pin on the bracket.
Note
The small spike on the bracket shall be

pointing downwards for correct fitting of the
stop pin!
A
B
xx0800000453
Parts:
• A: Bracket
• B: Stop pin
• C: Small spike
4 Secure the stop pin on the frame with its See the figure in
attachment screws. • Location of stop pin axis 1 on
page 295
5
DANGER

on page 53.

4 Repair
4.7.1 Removing motors
4.7 Motors
Introduction
This procedure describes how to remove motors on all axes of the robot.
Location of axis-1 and axis-2 motors

The axis-1 and axis-2 motors are located as shown in the figure.
Motors:
(1) = Axis-1 motor
(2) = Axis-2 motor
xx0900000302
A Attachment screws M5x16, quality Steel 8-A2F (7 pcs)

B Motor cover
C Attachment screws, axis-1 motor (4 pcs) + washers. See Tightening torques and
attachment screws on page 310
C Attachment screws, axis-2 motor (4 pcs) + washers. See Tightening torques and
D Connection box
E Axis-1 motor
E Axis-2 motor
F O-ring
G Hole
H Cable gland cover

4 Repair
Continued
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. (4) = Axis-4, axis-5 and axis-6 motors.
xx0900000303
A Markings inside armhouse, identifying the position of each motor

B Attachment screws, axis-3 motor (4 pcs) + washers. See Tightening torques and
B Attachment screws, axis-4, axis-5 and axis-6 motors (3x4 pcs) + washers.
Tightening torques and attachment screws on page 310
C Axis-3 motor
D Axis-4 motor
E Axis-5 motor
F Axis-6 motor
G O-ring (axis-4, axis-5 and axis-6)
H Armhouse

4 Repair
Continued
Connectors, axis-3 and axis-4 motors

The figure shows the connectors of motors axes 3-6.
MP5
FB5
FB4 FB6
MP4
MP3
FB3
MP6
xx0900000410
Required equipment
Equipment Note
on page 385.
Weights
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
Axis-6 motor 8 kg

4 Repair
Continued
CAUTION
All lifting equipment must be sized accordingly!

Action Note
calibration:
Position of robot
Use this procedure to place the robot in the position recommended in order to
facilitate replacement of motors.
Action Information
Axis-1, axis-4, axis-5 and axis-6 motor
• Move the robot to a position where the
wrist is pointing to the floor, as shown in
the figure. This will make it possible to
remove the motors without draining the
oil from the gearbox.
xx0800000388

4 Repair
Continued
Action Information
Axis-2 motor
lower arm rests firmly on the damper of
axes 2 and 3. Release the brake of axis
2 to be sure that the lower arm rests in
the end position.
xx1100000548
Axis-3 motor
• Move axis-2 to 0° and axis-3 to maximal
+. Release the brake of axis-3 to be sure
that the upper arm is completely vertical
and rests against the damper of axis-2
and axis-3.
Draining gearbox
Use this procedure to drain gearboxes, if needed.
Note
Draining of gearbox is only needed when removing the axes 2 and 3 motors.
Action Note
1 Axis-1 motor: -
• Draining of gearbox is not needed.
2 Axis-2 motor: How to drain the gearbox is described
• The gearbox has to be drained before in section:
removing the motor. • Changing the oil, axis-2 gearbox
on page 174
3 Axis-3 motor: How to drain the gearbox is described
• The gearbox has to be drained before in section:
removing the motor. • Changing the oil, axis-3 gearbox
on page 178
4 Axis-4, axis-5 and axis-6 motors: -
• Draining of gearbox oil is not needed if
robot is positioned as recommended.
Removing motors
Use this procedure to remove the axis-1, axis-2, axis-3, axis-4, axis-5 and axis-6
motors.
Note
The procedure contains information how to remove motors on all axes of the
robot. Some steps are only applicable to a certain motor. Follow the steps
carefully in order not to miss vital information!

4 Repair
Continued
Action Note
take actions accordingly prior to beginning the
repair procedure.
2 Move the robot to the recommended position See Removing motors on page 298.
for the motor that shall be removed. • Position of robot on page 301
3
DANGER
Turn off all:

area.
4 Check if the gearbox needs to be drained. See Removing motors on page 298.
• Draining gearbox on page 302
5 Only applicable to axis-3, axis-4, axis-5 and
axis-6 motors!
Remove the cover in the back of the arm house.
B
WARNING
The robot must never be run without the cover

in the armhouse fitted! It is a vital supporting
part of the robot.
A
xx0800000389
Parts:
• A: Cover
• B: Attachment screws (10 pcs)
+ washers.
6 Only applicable to motors on axes 1 and 2 How to remove the fan is detailed in
with fan fitted! section:
Remove the fan before starting the removal! • Installation of cooling fan for
motors (option) on page 101
7 Only applicable to axis-1 and axis-2 motors! See the figure in:
Remove the motor cover. • Location of axis-1 and axis-2
motors on page 298
Remove the cable gland cover. • Location of axis-1 and axis-2
motors on page 298
Remove the connection box. • Location of axis-1 and axis-2
motors on page 298
Note
Only needed if the motor shall be replaced with

a new one.

4 Repair
Continued
Action Note
10 Disconnect the motor cables.
Note
When removing the axis-3 motor, the

cables of the axis-4, axis-5 and axis-6
motors must be disconnected too. This
must be done in order to be able to
remove the bracket on top of the axis-
3 motor.
11 Only applicable to axis-3 motor!

Remove the bracket from the axis-3 motor.
xx0800000390
Parts:
• A: Axis-3 motor
• B: Bracket
12 In order to release the brakes of the motor to Connectors:
be removed, connect the 24 VDC power supply • Axis-1 motor: R2.MP1
to the motor. • Axis-2 motor: R2.MP2
Only applicable to motors axes 2 and 3!
• Axis-3 motor: R2.MP3
Release the brake of axis 2 untill the lower arm
firmly rests on the damper.
Connect to pins:
• + : pin 2
• -: pin 5
CAUTION
The connections for the motor brakes

(24 VDC connection) are phase de-
pendent. If the connection on the pins
is switched, it can cause severe dam-
age to vital parts.
13
Note

is used!

4 Repair
Continued
Action Note
14 Remove the attachment screws securing the See the figure in:
motor. • Location of axis-1 and axis-2
If needed use a 300 mm extension for bits 1/2" motors on page 298
(Motor axis 1).
15 If required, press the motor out of position by
fitting two screws in the threaded holes in the Note
motor flange.
Always use removal tools in pairs diag-
onal to each other.
16 Remove the motor!

CAUTION
Lift the motor gently in order not to

damage pinion or gears.
17 Only applicable to motor axis 1! See the figure in:

Cover the hole if replacement of motor axis 1 • Location of axis-1 and axis-2
is not immediate, in order to avoid contamina- motors on page 298
tion.
18 Only applicable to motors axes 4, 5 and 6! See the figure in:
Check that the o-ring also is removed. It might • Location of axis-1 and axis-2
stay in the armhouse when the motor is re- motors on page 298
moved.

4 Repair
4.7.2 Refitting motors
Introduction
This procedure describes how to refit motors on all axes of the robot.
WARNING
When a motor is replaced, make sure to use the correct type of new motor. Motors
of different types may not be compatible. See the Spare parts manual delivered
as a separate document on the documentation DVD.
Location of axis-1 and axis-2 motors

The axis-1 and axis-2 motors are located as shown in the figure.
Motors:
(1) = Axis-1 motor
(2) = Axis-2 motor
xx0900000302
A Attachment screws M5x16, quality Steel 8-A2F (7 pcs)

B Motor cover
C Axis-1 motor: Attachment screws(4 pcs) + washers. See Tightening torques
and attachment screws on page 310
C Axis-2 motor: Attachment screw (4 pcs) + washers. See Tightening torques and
D Connection box
E Axis-1 motor
E Axis-2 motor
F O-ring
G Hole
H Cable gland cover

4 Repair
Continued
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
(4) = Axis-4, axis-5 and axis-6 motors
xx0900000303
A Markings inside armhouse, identifying the position of each motor

B Attachment screws, axis-3 motor, (4 pcs) + washers. See Tightening torques
and attachment screws on page 310
B Attachment screws, axis-4, axis-5 and axis-6 motors, (3x4 pcs) + washers. See
Tightening torques and attachment screws on page 310
C Axis-3 motor
D Axis-4 motor
E Axis-5 motor
F Axis-6 motor
G O-ring (axis-4, axis-5 and axis-6)
H Armhouse

4 Repair
Continued
Connectors, axis-3 and axis-4 motors

The figure shows the connectors of the axis-3 and axis-4 motors.
MP5
FB5
FB4 FB6
MP4
MP3
FB3
MP6
xx0900000410
Required equipment
Equipment Note
on page 385.
Lifting tool, axis-2 For art. no. see Reference information.
Lifting tool, axis-3 For art. no. see Reference information.
Motors For spare part no. see Spare part lists on
page 391.
Weights
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

4 Repair
Continued
Motor Weight in kg
Axis-6 motor 8 kg
CAUTION
All lifting equipment must be sized accordingly!
Position of robot
Use this procedure to place the robot in the position recommended in order to
facilitate replacement of motors.
Action Information
Axis-1, axis-4, axis-5 and axis-6 motors
wrist is pointing to the floor, as shown in
the figure. This will make it possible to
remove the motors without draining the
oil from the gearbox.
xx0800000388
Axis-2 motor
lower arm rests firmly on the axis-3
damper. Release the axis-2 brake to be
sure that the lower arm rests in the end
position.
xx1100000548
Axis-3 motor
• Move axis-2 to 0° and axis-3 to maximal
+. Release the axis-3 brake to be sure
that the upper arm is completely vertical
and rests against the damper.
Filling oil in gearbox

Use this procedure to fill oil in gearbox, if needed.
Note
Filling oil in the gearbox is only needed when refitting motors axes 2 and 3.

4 Repair
Continued
Action Note
1 Axis-1 motor: -
• Filling gearbox oil not needed.
2 Axis-2 motor: How to fill oil in gearbox is described
• Refill oil in gearbox after refitting. in section:
• Changing the oil, axis-2 gear-
box on page 174
3 Axis-3 motor: How to fill oil in gearbox is described
• Refill oil in gearbox after refitting. in section:
• Changing the oil, axis-3 gear-
box on page 178
4 Axis-4, axis-5 and axis-6 motors: -
• Filling gearbox oil not needed.
Tightening torques and attachment screws

The table shows the tightening torques for all motors.
Motor Attachment screw Quality Tightening torque
Motor, axis 1 M8x25 8.8-A2F 22 Nm
Motor, axis 2 Screwlengths depending 8.8-A2F 35 Nm
on flange thickness on
page 310
Motor, axis 3 Screwlengths depending 8.8-A2F 22 Nm
on flange thickness on
page 310
Screwlengths depending on flange thickness

Screwlengths can vary depending on when the robot is delivered. The different
screwlengths depends on the different flange thickness of motors. Make sure to
use the correct screwlength! See table:
Motor axis 2 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
A Flange thickness

4 Repair
Continued
Preparations before the refitting of motors

Use this procedure to make necessary preparations before refitting motors.
Action Note
1
DANGER
Turn off all:

area.
2 Grind the paint on the surface carefully to get

a smoth surface.
3 Clean the surface from contamination such as
oil and dirt.
Remove any painting from the assembly sur-
faces, with a knife.
4 Make sure that the motor and the pinion are
not damaged or scratched.
5 Lightly lubricate the o-ring with grease.
6 Make sure the o-ring on the flange of the motor
is seated properly.
xx0900000082
Parts:
• A: Correct position of o-ring
• B: Incorrect position of o-ring !
Replace with a new o-ring if damaged!

4 Repair
Continued
Action Note
7 In order to release the brakes, connect the 24 Connectors:
VDC power supply. • Motor axis 1: R2.MP1
• Motor axis 2: R2.MP2
Connect to pins:
• + : pin 2
• -: pin 5
CAUTION
The connections for the motor brakes

(24 VDC connection) are phase de-
pendent. If the connection on the pins
is switched, it can cause severe dam-
age to vital parts.
Note
A fan is recommended to be used to avoid overheating of motor and gear in

applications with intensive motion (high average torque and/or short wait time)
of axes 1 and 2. IP54 is valid for cooling fan.
A fan is also recommended to be used if the environmental temperature is high.
How to install a fan is described in section Installation of cooling fan for motors
(option) on page 101.
Refitting motors
Use this procedure to refit motors axes 1, 2, 3, 4, 5 and 6.
Note
The procedure contains information how to refit motors on all axes of the robot.
Some steps are only applicable to a certain motor. Follow the steps carefully in
order not to miss vital information!
Action Information
1 See Refitting motors on page 306.
Note • Preparations before the refitting
of motors on page 311
Before starting the refitting of the motor, first
make the necessary preparations!
2
Note

is used!
3 Place the motor carefully in the gearbox.

4 Repair
Continued
Action Information
4 Fit the motor, making sure the motor pinion is Make sure that:
properly mated to the gear in the gearbox. • the motor is turned the correct
way
• the pinion or gear of the motor
does not get damaged!
5 Applicable to motor axis 3!
Make sure 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
6 Applicable to motors axes 4, 5 and 6!
Make sure that the wire exit hole of the motor
is in the correct position.
xx0900000062
Parts:
• A: Wire exit hole, motor axis 4
• B: Wire exit hole, motor axis 5
• C: Wire exit hole, motor axis 6
7 Only applicable to motors axes 4, 5 and 6!
Fit the attachment screws for the motor and
fasten them sligthly. The motor must be able
to move parallel to the gear during the adjust-
ment of the play.
8 Only applicable to motors axes 4, 5 and 6! See Adjusting the play of axis 4, 5 and
Adjust the play of the motor. 6 motors on page 316.
9 Secure the motor with its attachment screws Tightening torque and attachment
and washers. screws are specified in the table:
• Tightening torques and attach-
Note ment screws on page 310
Apply the correct tightening torque!
10 Disconnect the brake release voltage.

4 Repair
Continued
Action Information
11 Only applicable to motors axes 1 and 2! See the figure in:
Refit the connection box (if it has been re- • Location of axis-1 and axis-2
moved). motors on page 306
Note
Make sure that the o-ring is in place!
12 Applicable to motor axis 3!

Refit the bracket on motor axis 3.
xx0800000390
Parts:
• A: Motor axis 3
• B: Bracket
13 Reconnect the motor cables.
14 Applicable to motor axes 1 and 2! See the figure in:
Refit the cable gland and motor covers. • Location of axis-1 and axis-2
motors on page 306
Make sure that the o-ring is in place!
Note
Make sure that the cover is tightly

sealed!
15 Applicable to motors axis 2! How to fill oil in the gearbox is de-

Refill gearbox oil. scribed in sections:
on page 174
on page 178
16 Applicable to motors axes 3, 4, 5 and 6! If the gasket is damaged, it need to be
Make sure that the gasket on the cover on the replaced.
armhouse is intact.

4 Repair
Continued
Action Information
17 Applicable to motors axes 3, 4, 5 and 6! Make sure that the cover is tightly
Refit the cover in the back of the armhouse sealed.
with its attachment screws and washers.
WARNING
B
The cover on the armhouse must be fitted when
the robot is running. It is a vital part for the
stability of the robot.
A
xx0800000389
Parts:
• A: Cover
• B: Attachment screws M6x25,
quality 8.8-A2F (10 pcs)
Tightening torque:
• 14 Nm
18 Recalibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum, enclosed with the calibration
tools.
Axis Calibration is described in Calib-
rating with Axis Calibration method on
page 353.
General calibration information is in-
cluded in section Calibration on
page 341.
19
DANGER

when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on
page 53.

4 Repair
4.7.3 Adjusting the play of axis 4, 5 and 6 motors
4.7.3 Adjusting the play of axis 4, 5 and 6 motors
Required equipment
Equipment Note
Measuring tool For adjusting the play.
on page 385.
Adjusting the play of axis 4, 5 and 6 motors
Action Note
1 Fit the measuring tool at the rear of the motor.
2 Adjust the play on the motor by starting with a big play and then
gradually finding the smallest play. Use swift movements in order
to avoid noticing the magnetic field which causes the gears to stick
together. Follow the instructions for current motor:
Motor axis 4:
1 Turn the motor shaft six turns and find the smallest play
within this range.
Axis 5 motor:
1 Turn the outgoing shaft for axis 4 in intervals of 90° for one
full turn and find the smallest play for the axis 5 motor
within this range.
2 Turn the axis 5 motor one full turn at a time for a total of
five turns and find the smallest play within this range.
Axis 6 motor:
1 Turn the outgoing shaft for axis 4 in intervals of 90° for one
full turn and find the smallest play for the axis 6 motor
within this area.
five turns and find the smallest play for axis 6 within this
range.
three turns and find the smallest play for axis 6 within this
range.
3 Push or tap the motor in radial direction so that the play becomes
minimal within one motor turn, without the gear "chewing".

4 Repair
4.8.1 Replacing gearbox axis 1
4.8 Gearboxes
Location of gearbox
The gearbox is located as shown in the figure.
This exploded view only shows the principle of the assembly. The actual replacing
is recommended to be done with the robot resting on its side. See illustration in
section Replacing the base: Position of robot when replacing base from complete
arm system on page 250.
Type C
xx1200000637
A Frame
B Radial sealing
C Axis-1 gearbox with O-ring
D Harness pipe
E Washer (16 pcs)
F Attachment screws M10x100 quality Steel 12.9 Gleitmo (16 pcs)

4 Repair
Continued
xx0800000400
A Frame
B Radial sealing
C O-ring
D Axis-1 gearbox
E Washer (21 pcs)
F Attachment screws M8x80 quality Steel 12.9 Gleitmo (21 pcs)
Required equipment
Equipment Note
Gearbox See Spare part lists on page 391.
Other design than Type C: M8 (2 pcs)
Used to guide the gearbox during removal/re-
fitting.
on page 385.

4 Repair
Continued

Action Note
calibration:
Removing gearbox axis 1

Use this procedure to remove the gearbox.
Action Note
2 Drain the oil from the gearbox. How to drain the oil from the gearbox is
page 162
3 Move the robot to the calibration position.
4
DANGER
Turn off all:

working area.
5 Remove the axis 1 motor. See Removing motors on page 298.

4 Repair
Continued
Action Note
6 In order to reach gearbox axis 1, it is neces- How to remove the base from the com-
sary first to remove the base from the complete arm system is described in section:
plete arm system. • Removing the base on page 251
7 Fit a lifting lug in the uppermost hole for the
attachment screws securing the base, as
shown in the figure.
xx0800000440
Parts:
• A: Roundsling
• B: Lifting lug
• C: Uppermost attachment hole for
securing the base
• D: Gearbox axis 1
8
CAUTION
The gearbox weighs 27 kg.

accordingly!
9 Secure the gearbox in an overhead crane or

similar.
10 Remove the attachment screws securing the See the figure in:
gearbox. • Location of gearbox on page 317
11 Insert guide pins in two, diagonally located, Always use guide pins in pairs!
attachment holes in the gearbox.
12
Note
Whenever parting/mating motor and gear-

box, the gears may be damaged if excessive
force is used!
13
Note
There will be some eccess oil running out

of the gearbox when it is removed. Put some
exorbant material to catch the oil.

4 Repair
Continued
Action Note
14 Using caution slide the gearbox out onto the
guide pins and lift it away. Note
If necessary use removal tools to remove
the gearbox. Always use removal tools in pairs diagon-
al to each other.
Refitting gearbox axis 1

Use this procedure to refit the gearbox.
Action Note
1
DANGER
Turn off all:

working area.
2 Fit a lifting lug in the uppermost hole for

the attachment screws securing the base,
as shown in the figure.
xx0800000440
Parts:
• A: Roundsling
• B: Lifting lug
• C: Uppermost attachment hole for
securing the base
• D: Gearbox axis 1

4 Repair
Continued
Action Note
3 Only valid for Other design than Type C:
Note
Check, when fitting the lifting lug, that both

oil plugs will be placed in the correct posi-
tion after the gearbox is fitted as shown in
the figure. The oil plugs shall be placed in A
the openings in the frame.
xx0800000441
Parts:
• A: Opening for oil plug in frame
• B: Oil plug
4 Apply grease on the o-ring. See the figure in:
• Location of gearbox on page 317
Replace o-ring if damaged.
6 Fit guide pins into two of the holes for the Always use guide pins in pairs!
attachment screws.
7
Note

force is used!
8
CAUTION

accordingly!
9 Lift the gearbox onto the guide pins and Only valid for Other design than Type C:
slide it into position, using caution. Double check that the oil plugs are in the
correct position.
10 Secure the gearbox with its attachment See the figure in:
screws. • Location of gearbox on page 317
Tightening torque:
• Other design than Type C: 35 Nm
• Type C: 68 Nm
11 Refit the base on the complete arm system. How to refit the base on the complete arm
system is described in section:
• Refitting the base on page 255

4 Repair
Continued
Action Note
12 Refit the cable harness in the base, the See Replacing gearbox axis 1 on page 317.
frame and the lower arm. • Refitting the cable harness in the
base on page 228
frame on page 225
page 234
.
13 Refill oil in the gearbox. How to fill oil in gearbox is described in
section:
page 162
15
DANGER

on page 53.

4 Repair
Location of gearbox axis 2

xx0800000438
A Attachment screws M12x50 quality Steel 12.9 Gleitmo (15 pcs)

B Washers (15 pcs)
C Gearbox axis 2
D O-ring
E Frame
Required equipment

Rotation tool 3HAB7887-1
Lifting accessories - Roundslings.

4 Repair
Continued

Other tools and procedures may be These procedures include refer-
required. See references to these ences to the tools required.
procedures in the step-by-step in-
structions below.

Action Note
calibration:

WARNING
The procedure details how to replace the gearbox without removing the cable
harness, only by loosening it. This means that the upper and lower arm will be
separated from the frame but still be connected to the frame through the cabling.
Be careful not to damage the cables!
Action Note
1 Decide which calibration routine to
use, and take actions accordingly prior
to beginning the repair procedure.

4 Repair
Continued
Action Note
2 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
3
DANGER
Turn off all:

working area.
4 Drain the gearbox. How to drain the gearbox is described in sec-

tion:
• Changing the oil, axis-2 gearbox on
page 174

4 Repair
Continued
Action Note
5 Loosen the cabling from the lower arm
by removing two cable brackets and a
cable strap.
B
C
xx1100000946
A Cable bracket
B Cable bracket
C Cable strap
6 Attach a roundsling around the upper
arm house.
7 Unload the weight of the lower and
upper arm package by stretching the
roundslings with the overhead crane.
Turn on the power temporarily and re-
lease the brakes of axis 2 to rest the
weight onto the roundslings.
8
DANGER
Turn off all:

working area.

4 Repair
Continued
Action Note
9 Remove the attachment screws and
washers that secure the lower arm to
the axis 2 gearbox.
xx1200000085
10 Remove the lower and upper arm

package from the frame.
WARNING
The cable harness is still installed on

the robot! Make sure not to damage
the cables or the cable brackets on the
robot.
11
CAUTION

All lifting accessories used must be
sized accordingly!

4 Repair
Continued
Action Note
12 Fit a lifting lug in the uppermost hole
for the attachment screws that secure A
the lower arm to the gearbox.
xx0800000445
Parts:
• B: Lifting lug
• C: Holes for attachment screws securing
the lower arm to gearbox axis 2
13 Secure the gearbox with a roundsling
in an overhead crane or similar.
14 Remove the attachment screws and See the figure in:
washers that secure the gearbox to the • Location of gearbox axis 2 on page 324
frame.
15 Fit guide pins to help guiding the
gearbox out from the frame.
16 If necessary, use removal tools to re-
move the gearbox. Note
Always use removal tools in pairs diagonal to

each other.
17 Remove the gearbox.
CAUTION
Use caution in order not to damage

gearbox or pinion!

4 Repair
Continued
Refitting gearbox axis 2

Action Note
1
DANGER
Turn off all:

working area.
2
CAUTION

accordingly!
3 Fit a lifting lug in the uppermost hole for

A
the attachment screws securing the lower
arm to the gearbox.
xx0800000445
Parts:
• B: Lifting lug
• C: Holes for attachment screws
securing the lower arm to gearbox
axis 2.
5 Apply some grease on the o-ring before fit- See the figure in:
ting. • Location of gearbox axis 2 on
page 324
6 Fit two guide pins in opposite holes in the
frame.
7 Secure the gearbox with a roundsling in an
overhead crane or similar.

4 Repair
Continued
Action Note
9 Lift the gearbox onto the guide pins and Article number is specified in Required
slide it into position while rotating the motor equipment on page 324.
pinion to find the mating position. Use a ro-
tation tool.
Note
The position of the oil plug shall be accord-

ing to the illustration.
xx1000000307
Parts:
• A: Position of oil plug on gearbox
10 Secure the gearbox with its attachment See screw dimension in the figure in:
screws and washers. • Location of gearbox axis 2 on
page 324
Tightening torque: 110 Nm
page 204.
12 Fit the guide pins to the gearbox.
13 Lift the upper and lower arms into mounting
position and guide them in place with the
guide pins.
It might be necessary to rotate the motor
pinion with the rotating tool to find the mat-
ing position.
14 Refit the attachment screws that secure the A
lower arm to the axis 2 gearbox.
B C D E
xx0800000377
Tightening torque:
• 110 Nm
Parts:
• A: Frame
• C: Lower arm
quality 12.9 steel Gleitmo (18 pcs)

4 Repair
Continued
Action Note
15 Refit the cable brackets and cable strap to
the lower arm.
B
C
xx1100000946
A Cable bracket
B Cable bracket
C Cable strap
16 Refill the gearbox with lubrication oil. How to fill the gearbox with oil is de-
scribed in section:
on page 174
18
DANGER

on page 53.

4 Repair
Location of gearbox axis 3

Type C
xx1200000638
A Upper arm
B Axis-3 gearbox
C Washers (16 pcs)
D Attachment screws M10x50 quality Steel 12.9 Gleitmo (16 pcs)

4 Repair
Continued
B
C
D
E
xx0800000398
A Upper arm
B O-ring
C Axis-3 gearbox
D Washers (18 pcs)
E Attachment screws M8x80 quality Steel 12.9 Gleitmo (18 pcs)
Required equipment

Gearbox See Spare part lists on page 391.
Other design than Type C: M8 (2
pcs)
Used to guide the gearbox and the
upper arm during removal/refitting.
Rotation tool 3HAB7887-1

4 Repair
Continued

Other tools and procedures may be These procedures include refer-
required. See references to these ences to the tools required.
procedures in the step-by-step in-
structions below.

Action Note
calibration:

WARNING
The procedure details how to replace the gearbox without removing the cable
harness. This means that the upper and lower arm will be separated but still be
connected to eachother through the cabling. Be careful not to damage the cables!
Action Note
2 Drain the gearbox. How to drain the gearbox is described in
section:
on page 178

4 Repair
Continued
Action Note
figure.
xx0800000336
4
DANGER
Turn off all:

working area.
5 Unscrew the attachment screws securing

the cable harness to the lower arm by the
the two cable brackets and a cable strap.
B
C
xx1100000946
A Cable bracket
B Cable bracket
C Cable strap
6 Loosen the cabling from the lower arm by
unhooking the two cable brackets.
CAUTION
The cable harness is still mounted in other

parts of the robot. Make sure not to damage
the cable harness or any cable brackets in
the continued removal.
arm. the upper arm on page 264
8 Connect the 24 VDC power supply to the
axis-3 motor and release the brakes.

4 Repair
Continued
Action Note
9 Releasing the brakes of the axis-3 motor
unloads the weight of the upper arm by
stretching the roundslings.
10 Remove the attachment screws that secure See the figure in:
the upper arm to the lower arm. • Location of the complete upper arm
on page 259
Note
Do not remove the attachment screws se-

curing the gearbox axis 3 to the armhouse!
11
CAUTION

accordingly!
12 Remove the upper arm from the lower arm

and leave it hanging in the air. WARNING
CAUTION The cable harness is still installed on the

robot! Make sure not to damage the cable
When the upper arm no longer is attached harness or the cable brackets on the ro-
to the robot, the armhouse has a tendency bot.
to drop down a little. In order to prevent this
is to rise the front end of the upper arm a
little before removing the attachment screws
securing the upper arm.
13
CAUTION

accordingly!
14 Remove two attachment screws diagonally Always use guide pins in pairs!
located and insert guide pins.
15 Remove the remaining attachment screws See the figure in:
that secures the gearbox. • Location of gearbox axis 3 on
page 333
16
Note
There will be some surplus oil in the gear-

box. Place some absorbant cloth or similar
under the gearbox.
17 Slide the gearbox carefully out onto the

guide pins and lift it away. Note
If necessary, use a pair of screws to push
out the gearbox. Always use removal tools in pairs diagon-
al to each other.
CAUTION
Remaining oil will drain out from the gear-

box cavity when the gearbox is lifted out.

4 Repair
Continued
Refitting the gearbox axis 3

Action Note
1
DANGER
Turn off all:

working area.
2
CAUTION

accordingly!

Remove any painting or other contamination
from the assembly surfaces, with a knife.
4 Apply some grease on the o-ring before fit- See the figure in:
ting it to the gearbox. • Location of gearbox axis 3 on
page 333
5 Fit two guide pins in two opposite screw Always use guide pins in pairs!
holes in the upper arm.
6 Remove the arm house cover.
7 Attach the rotation tool on the axis-3 motor.
9 Lift the gearbox onto the guide pins.
10
Note

force is used!
11 Slide the gearbox into position while rotating Article number for the rotation tool is
the motor pinion to find the mating position. specified in Required equipment on
Use a rotation tool. page 334.
Tip
Two persons are required for this step since

the upper arm is hanging freely in the air.
One person needs to hold the upper arm
still while the other fits the gearbox into the
upper arm.
12 Rotate the motor pinion and slide the gear-

box into position.

4 Repair
Continued
Action Note
13 Secure the gearbox with its attachment See the figure in:
screws and washers. • Location of gearbox axis 3 on
page 333
14 Remove the guide pins and replace them
with the remaining attachment screws.
page 204.
16 Fit guide pins in the upper arm. Specified in Required equipment on
page 334.
17 Move the upper arm to its mounting posi-
tion.
(With the brakes of the axis 3 motor still re-
leased.)
18 Refit the upper arm to the lower arm with See the figure in:
its attachment screws. • Location of the complete upper arm
on page 259
Tightening torque:
• Type C: 50 Nm and 90° angle
• Other design than Type C: 35 Nm
19 Remove the guide pins and replace with the
remaining attachment screws.
20 Remove the 24 VDC power supply.
21 Refit the upper armhouse cover with its at- Tightening torque: 14 Nm.
tachment screws and washers. Make sure that the cover is tightly sealed.
WARNING
The cover on the armhouse must be fitted B

when the robot is running. It is a vital part
for the stability of the robot.
A
xx0800000389
Parts:
• A: Cover
• B: Attachment screws M6x25,
quality 8.8-A2F (10 pcs)

4 Repair
Continued
Action Note
22 Refit the two cable brackets and a cable
strap to the lower arm.
B
C
xx1100000946
A Cable bracket
B Cable bracket
C Cable strap
23 Refill the gearbox with lubrication oil. How to fill the gearbox with oil is de-
scribed in section:
on page 178
25
DANGER

on page 53.

5 Calibration
5.1.1 Introduction and calibration terminology
5 Calibration
5.1 Introduction to calibration
5.1.1 Introduction and calibration terminology
Calibration information
This chapter includes general information about the recommended calibration
methods and also the detailed procedures for updating the revolution counters,
checking the calibration position etc.
Detailed instructions of how to perform Axis Calibration are given on the
FlexPendant during the calibration procedure. To prepare calibration with Axis
Calibration method, see Calibrating with Axis Calibration method on page 353.
Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.
Calibration terminology
Term Definition
Calibration method A collective term for several methods that might be
available for calibrating the ABB robot. Each method
contains calibration routines.
Synchronization position Known position of the complete robot where the
angle of each axis can be checked against visual
synchronization marks.
Calibration position Known position of the complete robot that is used
for calibration of the robot.
Standard calibration A generic term for all calibration methods that aim
to move the robot to calibration position.
Fine calibration A calibration routine that generates a new zero posi-
tion of the robot.
Reference calibration A calibration routine that in the first step generates
a reference to current zero position of the robot. The
same calibration routine can later on be used to re-
calibrate the robot back to the same position as when
the reference was stored.
This routine is more flexible compared to fine calib-
ration and is used when tools and process equipment
are installed.
Requires that a reference is created before being
used for recalibrating the robot.
Update revolution counter A calibration routine to make a rough calibration of
each manipulator axis.
Synchronization mark Visual marks on the robot axes. When marks are
aligned, the robot is in synchronization position.

5 Calibration
5.1.2 Calibration methods
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration Axis Calibration or Cal-
position. ibration Pendulum i
Standard calibration data is found on the SMB
(serial measurement board) or EIB in the robot.
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at synchronization posi-
al) tion, the Absolute accuracy calibration also
compensates for:
• Mechanical tolerances in the robot
structure
• Deflection due to load
Absolute accuracy calibration focuses on pos-
itioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with absolute accuracy has
a sticker next to the identification plate of the
robot.
To regain 100% absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy!
xx0400001197
i The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use
the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in the calibration
menu on the FlexPendant.
If no data is found related to standard calibration, Calibration Pendulum is used as default.

5 Calibration
Continued
Brief description of calibration methods

Calibration Pendulum method
Calibration Pendulum is a standard calibration method for calibration of all ABB
robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).
Two different routines are available for the Calibration Pendulum method:
• Calibration Pendulum II
• Reference calibration
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.
Axis Calibration method

Axis Calibration is a standard calibration method for calibration of IRB 4600 and
is the most accurate method for the standard calibration. It is the recommended
method in order to achieve proper performance.
The following routines are available for the Axis Calibration method:
• Fine calibration
• Update revolution counters
• Reference calibration
The calibration equipment for Axis Calibration is delivered as a toolkit.
An introduction to the calibration method is given in this manual, see Calibrating
The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.
CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute
Accuracy calibration is used as a TCP calibration. The CalibWare tool guides
through the calibration process and calculates new compensation parameters.
This is further detailed in the Application manual - CalibWare Field 5.0.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after motor and transmission replacements that do not include
taking apart the robot structure, standard calibration is sufficient. Standard
calibration also supports wrist exchange.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 386.
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.

5 Calibration
5.1.3 When to calibrate
5.1.3 When to calibrate
When to calibrate
The system must be calibrated if any of the following situations occur.
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,
according to information in this manual.
If the robot has absolute accuracy calibration, it is also recommended, but not
always necessary to calibrate for new absolute accuracy.
The resolver values will change when parts affecting the calibration position are
replaced on the robot, for example motors or parts of the transmission.
The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See
Updating revolution counters on page 349. This will occur when:
• The battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are
connected at the first installation.
The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot
is changed, it needs to be recalibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.

5 Calibration
5.2.1 Synchronization marks and synchronization position for axes
5.2 Synchronization marks and axis movement directions
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
Synchronization marks, IRB 4600

The figures show the positions of the synchronization marks for all robot variants.
IRB 4600 - 60/2.05, -45/2.05, 40/2.55, -20/2.50
xx0800000312
A Synchronization mark, axis 1

B Synchronization mark, axis 2
C Synchronization mark, axis 3

5 Calibration
Continued
IRB 4600 - 60/2.05, -45/2.05, 40/2.55
xx0800000313
D Synchronization mark, axis 4

E Synchronization mark, axis 5
F Synchronization mark, axis 6

5 Calibration
Continued
IRB 4600 -20/2.50
xx0800000320
D Synchronization mark, axis 4

E Synchronization mark, axis 5
IRB 4600 -20/2.50
xx0800000321
F Synchronization mark, axis 6

5 Calibration
5.2.2 Calibration movement directions for all axes
5.2.2 Calibration movement directions for all axes
Overview
When calibrating, the axis must consistently be run towards the calibration position
in the same direction in order to avoid position errors caused by backlash in gears
and so on. Positive directions are shown in the graphic below.
Calibration service routines will handle the calibration movements automatically
and these might be different from the positive directions shown below.
Manual movement directions, 6 axes

Note! The graphic shows an IRB 7600. The positive direction is the same for all
6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the
opposite direction!
xx0200000089

5 Calibration
5.3 Updating revolution counters
Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Coupled axes
When updating the revolution counters for a coupled axis, also the axis it is coupled
to needs to be at its synchronization position for the update to be correct; i.e. axis
4 needs to be in synchronization position when updating axis 5 and 6.
With reversed coupled joints, the relationship is the opposite, i.e. axis 4 needs to
be in synchronization position to update axis 3.
Coupled axes
IRB 910 SC
IRB 1600ID
IRB 1660ID
IRB 2600ID
IRB 4450S
IRB 1410
IRB 1520
IRB 1600
IRB 2400
IRB 2600
IRB 4400
IRB 4600
IRB 140
Axis 4, 5, 6 x x x x x x x
Axis 5, 6 x x x x x
Axis 4, 3 x
Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.
Action Note
1 Select axis-by-axis motion mode.
2 Jog the manipulator to align the synchron- See Synchronization marks and synchron-
ization marks. ization position for axes on page 345.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 350.
Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important
to make sure that axes 4 and 6 of the following mentioned manipulators are
positioned correctly. The axes can be calibrated at the wrong turn, resulting in an
incorrect manipulator calibration.
Make sure the axes are positioned according to the correct calibration values, not
only according to the synchronization marks. The correct values are found on a
label, located either on the lower arm, underneath the flange plate on the base or
on the frame.
At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at
power up before the revolution counters are updated.

5 Calibration
Continued
If one of the following mentioned axes are rotated one or more turns from its
calibration position before updating the revolution counter, the correct calibration
position will be lost due to non-integer gear ratio. This affects the following
manipulators:
Manipulator variant Axis 4 Axis 6
IRB 4600 No No
If the synchronization marks seem to be wrong (even if the motor calibration data
is correct), try to rotate the axis one turn, update the revolution counter and check
the synchronization marks again (try both directions, if needed).
Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).
Action
1 On the ABB menu, tap Calibration.
xx1500000942

5 Calibration
Continued
Action
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943
3 This step is valid for RobotWare 6.02 and later.

Calibration method used at factory for each axis is shown, as well as calibration
method used during last field calibration.
Tap Manual Method (Advanced).
xx1500000944

5 Calibration
Continued
Action
4 A screen is displayed, tap Rev. Counters.
en0400000771
5 Tap Update Revolution Counters....

A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
6 Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
7 A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the selected revolution counters and removes the tick from
the list of axes.
8
CAUTION
If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi-

tioning, which in turn may cause damage or injury!
Check the synchronization position very carefully after each update. See Checking
the synchronization position on page 369.

5 Calibration
5.4.1 Description of Axis Calibration
5.4 Calibrating with Axis Calibration method
Instructions for Axis Calibration procedure given on the FlexPendant

This manual contains a brief description of the method, additional information to
the information given on the FlexPendant, article number for the tools and images
of where to fit the calibration tools on the robot.
Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis
at the time. The robot axes are both manually and automatically moved into position,
as instructed on the FlexPendant.
A fixed calibration pin/bushing is installed on each robot axis at delivery.
The Axis Calibration procedure described roughly:
• A removable calibration tool is inserted by the operator into a calibration
bushing on the axis chosen for calibration, according to instructions on the
FlexPendant.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools
from ABB. Using other pins in the calibration bushings may cause severe
damage to the robot and/or personnel.
WARNING
The calibration tool must be fully inserted into the calibration bushing, until
the steel spring ring snaps into place.
• During the calibration procedure, RobotWare moves the robot axis chosen
for calibration so that the calibration tools get into contact. RobotWare records
values of the axis position and repeats the coming-in-contact procedure
several times to get an exact value of the axis position.
WARNING
Risk of pinching! The contact force for large robots can be up to 150 kg.
Keep a safe distance to the robot.
• The axis position is stored in RobotWare with an active choice from the
operator.

5 Calibration
Continued
Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the
beginning of the procedure on the FlexPendant.
Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling
or equipment fitted to the robot.
Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the
robot is dressed with tools, process cabling or other equipment.
Also choose this routine if the robot is suspended.
If calibrating the robot with reference calibration there must be reference values
created before repair is made to the robot, if values are not already available.
Creating new values requires possibility to move the robot. The reference values
contain positions of all axes, torque of axes and technical data about the tool
installed. A benefit with reference calibration is that the current state of the robot
is stored and not the state when the robot left the ABB factory. The reference value
will be named according to tool name, date etc.
Follow the instructions given in the reference calibration routine on the FlexPendant
to create reference values.
When reference calibration is performed, the robot is restored to the status given
by the reference values.
Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
Validation
In the mentioned routines, it is also possible to validate the calibration data.
Position of robot axes

The axis chosen for calibration is automatically run by the calibration program to
its calibration position during the calibration procedure.
In order for the axis to be able to be moved to calibration position, or in order for
getting proper access to the calibration bushing, other axes might need to be
jogged to positions different from 0 degrees. Information about which axes are
allowed to be jogged will be given on the FlexPendant. These axes are marked
with Unrestricted in the FlexPendant window.
How to calibrate a suspended robot

The IRB 4600 is calibrated floor standing in factory, prior to shipping.
To calibrate a suspended robot, reference calibration must be used. Reference
values for a suspended robot must be created with the robot mounted at its working
position, not standing on a floor.
To calibrate a suspended robot with the fine calibration routine, the robot must
first be taken down and then be mounted standing on the floor.

5 Calibration
5.4.2 Calibration tools for Axis Calibration
Calibration tool set

The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration bushings may cause severe damage to
the robot and/or personnel.

Calibration tool box, 3HAC062326-001 Delivered as a set of calibration tools.
Axis Calibration Required if Axis Calibration is the valid calib-
ration method for the robot.
Contains a removal tool for removing special
protection plugs on the turning disk.
Examining the calibration tool

Check prior to usage
Before using the calibration tool, make sure that the tube insert, the plastic
protection and the steel spring ring are present.
WARNING
If any part is missing or damaged, the tool must be replaced immediately.
xx1500001914
A Tube insert
B Plastic protection
C Steel spring ring

5 Calibration
Continued
Periodic check of the calibration tool

If including the calibration tool in a local periodic check system, the following
measures should be checked.
• Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on
calibration tool size).
• Straightness within 0.005 mm.
xx1500000951
A Outer diameter

5 Calibration
5.4.3 Installation locations for the calibration tools
Location of fixed calibration items

The figure shows how the robot is equipped with items for installation of calibration
tools for Axis Calibration (fixed calibration pins and/or bushings). The figure does
not show installed calibration tools.
A fixed calibration pin and a bushing for the movable calibration tool are located
on each axis as follows.
If there is not enough space on an axis to install a fixed calibration pin, the axis is
equipped with two bushings instead, for installation of two calibration tools when
calibration is carried out. This is shown in the figure.
xx1600000641

5 Calibration
Continued
xx1600000642
IRB 4600 - 20/2.50
xx1600000643

5 Calibration
Continued
Spare parts
When calibration is not being performed, a protective cover and an o-ring should
always be installed on the fixed calibration pin as well as a protective plug, included
a sealing, in the bushing. Replace damaged parts with new, if needed.
Spare part Article number Note
Protection cover and plug set 3HAC059487-001 Contains replacement calibration
(protection type pin covers and protective plugs
Standard) for the bushing.
Protective plug on turning disc 3HAC057511-001 Only on IRB 4600 - 20/2.50.
Replace if damaged or missing.

5 Calibration
5.4.4 Axis Calibration - Running the calibration procedure
Required tools
The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration holes may cause severe damage to the
robot and/or personnel.

Calibration tool box, Axis 3HAC062326-001 Delivered as a set of calibration tools.
Calibration Required if Axis Calibration is the valid
calibration method for the robot.
Contains a removal tool for removing
special protection plugs on the turning
disk.
Required consumables
Consumable Article number Note
Clean cloth -
Spare parts
Spare part Article number Note

Protection cover and plug set 3HAC059487-001 Contains replacement calibration
(protection type pin covers and protective plugs
Standard) for the bushing.
Protective plug on turning disc 3HAC057511-001 Only on IRB 4600 - 20/2.50.
Overview of the calibration procedure on the FlexPendant

Use the following list to learn about the calibration procedure before running the
RobotWare program on the FlexPendant. It gives you a brief overview of the
calibration procedure sequence.
After the calibration method has been called for on the FlexPendant, the following
sequence will be run.
1 Choose calibration routine. The routines are described in Routines in the
calibration procedure on page 354.
2 Choose which axis/axes to calibrate.
3 The robot moves to synchronization position.
4 Validate the synchronization marks.

5 Calibration
Continued
5 The robot moves to preparation position.

6 Remove the protective cover from the fixed pin and the protection plug from
the bushing, if any, and install the calibration tool.
Use the removal tool included in the calibration tool box to remove the special
protection plug(s) on the turning disc.
IRB 4600 - 20/2.50:
xx1700000905
When calibrating axis 6, push in the calibration tool into the turning disc until
the snap ring engages, no further.
7 The robot performs a measurement sequence by rotating the axis back and
forth.
8 Remove the calibration tool and reinstall the protective cover on the fixed
pin and the protection plug in the bushing, if any.
Refit the protection plug(s) to the turning disc, push until the steel spring ring
snaps into place.
9 The robot moves to verify that the calibration tool is removed.
10 Choose whether to save the calibration data or not.
Calibration of the robot is not finished until the calibration data is saved, as last
step of the calibration procedure.
Preparation prior to calibration

The calibration procedure is described in the FlexPendant while conducting it.
Action Note
1
DANGER
While conducting the calibration, the robot needs

to be connected to power.
Make sure that the robots working area is empty,
as the robot can make unpredictable movements.
2 Wipe the calibration tool clean. Use a clean cloth.
Note
The calibration method is exact. Dust, dirt or color

flakes will affect the calibration value.

5 Calibration
Continued
Starting the calibration procedure

Use this procedure to call for the Axis Calibration method on the FlexPendant.
Action Note
1 On the ABB menu, tap Calibration.
xx1500000942
2 All mechanical units connected to the system are

shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943

5 Calibration
Continued
Action Note
3 Calibration method used at factory for each axis The FlexPendant will give all inform-
is shown, as well as calibration method used for ation needed to proceed with Axis
the robot during last field calibration. Calibration.
Tap Run Calibration Method. The software will
automatically call for the procedure for the valid
calibration method.
xx1500000944
4 Follow the instructions given on the FlexPendant. A brief overview of the sequence
that will be run on the FlexPendant
is given in Overview of the calibra-
tion procedure on the FlexPendant
on page 360.
Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished,
the RobotWare program needs to be started again. Use this procedure to take
required action.
Situation Action
The three-position enabling device on the Press and hold the three-position enabling
FlexPendant has been released during robot device and press Play.
movement.
The RobotWare program is terminated with Remove the calibration tool, if it is installed,
PP to Main. and restart the calibration procedure from
the beginning. See Starting the calibration
procedure on page 362.
If the calibration tool is in contact the robot
axis needs to be jogged in order to release
the calibration tool. Jogging the axis in wrong
direction will cause the calibration tool to
break. Directions of axis movement is shown
in Calibration movement directions for all
axes on page 348
Axis Calibration with SafeMove option

To be able to run Axis Calibration SafeMove needs to be unsynchronized. The Axis
Calibration routine recognizes if the robot is equipped with SafeMove and will force
SafeMove to unsynchronize automatically.

5 Calibration
Continued
However, SafeMove may generate other warning messages anytime during the
Axis Calibration routine.
Safety controller not synchronized - SafeMove message
Action Note
1 SafeMove generates the message "Safety control-
ler not synchronized".
xx1500002480
2 Confirm unsynchronized state by pressing Ac-

knowledge to continue Axis Calibration proced-
ure.
3 Restart Axis Calibration procedure by pressing
Play.
Unsynchronized speed exceeded - SafeMove message while saving robot data
Action Note
1 SafeMove generates the message "Unsynchron-
ized speed exceeded" while saving robot data.
xx1500002481
2 Press Acknowledge to continue Axis Calibration

procedure.
Play.

5 Calibration
Continued
Unsynchronized time limit expired - SafeMove message anytime during Axis Calibration routine
Action Note
1 SafeMove generates the message "Unsynchron-
ized time limit expired" (anytime).
xx1500002482
2 Press OK to continue Axis Calibration procedure.

Play.
After calibration
Action Note
1 Check the o-ring on the fixed calibration pin.
2 Reinstall the protective cover on the fixed calibra-
tion pin on each axis, directly after the axis has
been calibrated.
Replace the cover with new spare part, if missing
or damaged.
xx1600002102
Protection cover and plug set: .

3HAC059487-001 (protection type
Standard)

5 Calibration
Continued
Action Note
3 Reinstall the protective plug and sealing in the
bushing on each axis, directly after the axis has
been calibrated. Ensure that the sealing is not
damaged.
Replace the plug and the sealing with new spare
part, if missing or damaged.
xx1500000952
Protection cover and plug set: .

3HAC059487-001 (protection type
Standard)
4 Refit the special protection plug to the turning IRB 4600 - 20/2.50
disc using the tool included in the calibration tool
box.
xx1700000905
5 Remove the tool from the protection plug. IRB 4600 - 20/2.50
xx1700000906

5 Calibration
5.5 Calibrating with Calibration Pendulum method
5.5 Calibrating with Calibration Pendulum method
Where to find information for Calibration Pendulum

Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.

5 Calibration
5.6 Verifying the calibration
5.6 Verifying the calibration
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
Verifying the calibration

Use this procedure to verify the calibration result.
Action Note
1 Run the calibration home position program twice. See Checking the synchron-
Do not change the position of the robot axes after running ization position on page 369.
the program!
2 Adjust the synchronization marks when the calibration is This is detailed in section
done, if necessary. Synchronization marks and
synchronization position for
axes on page 345.
3 Write down the values on a new label and stick it on top
of the calibration label.
The label is located on the lower arm.
4 Remove any calibration equipment from the robot.

5 Calibration
5.7 Checking the synchronization position
5.7 Checking the synchronization position
Introduction
Check the synchronization position of the robot before beginning any programming
of the robot system. This may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the FlexPendant.
Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 On ABB menu tap Program editor.
2 Create a new program.
3 Use MoveAbsJ in the Motion&Proc menu.
4 Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0
5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 345 and Updating revolution
counters on page 349.
Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 On the ABB menu, tap Jogging.
2 Tap Motion mode to select group of axes
to jog.
3 Tap to select the axis to jog, axis 1, 2, or
3.
4 Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
5 Check that the synchronization marks for See Synchronization marks and synchron-
the axes align correctly. If they do not, up- ization position for axes on page 345 and
date the revolution counters. Updating revolution counters on page 349.

6 Decommissioning
6.1 Introduction
6 Decommissioning
6.1 Introduction
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
General
All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.

6 Decommissioning
6.2 Environmental information
6.2 Environmental information
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Batteries, NiCad or Lithium Serial measurement board
Copper Cables, motors
Cast iron/nodular iron Base, lower arm, upper arm
Steel Gears, screws, base frame, and so on.
Neodymium Brakes, motors
Plastic/rubber Cables, connectors, drive belts, and so on.
Oil, grease Gearboxes
Aluminium Covers, synchronization brackets
Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.
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.

6 Decommissioning
6.3 Scrapping of robot
6.3 Scrapping of robot
Important when scrapping the robot
DANGER
When a robot is disassembled while being scrapped, it is very important to

remember the following before disassembling starts, in order to prevent injuries:
• Always remove all batteries from the robot. If a battery is exposed to heat,
for example from a blow torch, it will explode.
• Always remove all oil/grease in gearboxes. If exposed to heat, for example
from a blow torch, the oil/grease will catch fire.
• When motors are removed from the robot, the robot will collapse if it is not
properly supported before the motor is removed.

7 Robot description
7.1 Type C of IRB 4600
7 Robot description
7.1 Type C of IRB 4600
Type C - alternative gearboxes

Type C of IRB 4600 have an alternative supplier of the axis-1 and axis-3 gearboxes.
How to know which of the types is described, in the manual

Throughout the manual the alternative gearboxes are described as "Type C". Other
types of gearboxes are called "Other design than Type C". The manual describes
all the types of gearboxes.
Interchangeable parts
Type C gearboxes are not interchangeable with other designs of the axis-1 and
axis-3 gearboxes.
Notable changes connected to the Type C gearboxes

• Dimension and number of attachments screws are different.
• Washers between the lower arm and axis-3 gearbox, are different.
• Tightening torques are different.
• Tightening torque with angle 90 degrees added when the lower arm is secured
to the axis-3 gearbox.
• The frame and base are redesigned to fit the axis-1 gearbox and are not
compatible with other designs of the gearbox. This affects the installation of
additional mechanical stops on axis 1 and the values of possible restricted
working range.

8 Reference information
8.1 Introduction
8.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

8.2 Applicable standards
Note
The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.
Standards, EN ISO
The product is designed in accordance with the requirements of:
Standard Description
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850:2015 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-1:2011 Robots for industrial environments - Safety requirements -Part
1 Robot
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
ISO 9283:1998 Manipulating industrial robots, performance criteria, and related
test methods
EN ISO 14644-1:2015 i Classification of air cleanliness
EN ISO 13732-1:2008 Ergonomics of the thermal environment - Part 1
EN 61000-6-4:2007 + EMC, Generic emission
A1:2011
IEC 61000-6-4:2006 +
A1:2010
(option 129-1)
EN 61000-6-2:2005 EMC, Generic immunity
IEC 61000-6-2:2005
EN IEC 60974-1:2012 ii Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-10:2014 ii Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part
1 General requirements
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only robots with protection Clean Room.
ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.
European standards
EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design

Continued
Other standards
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require-
ments

8.3 Unit conversion
8.3 Unit conversion
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

8.4 Screw joints
8.4 Screw joints
General
This section describes how to tighten the various types of screw joints on the IRB
4600.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.
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.
Whenever used, this is specified in the instructions, and in such cases, no other
type of replacement screw is allowed. Using other types of screws will void any
warranty and may potentially cause serious damage or injury.
Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the
screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating
disappears. After this the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber
type should be used.
Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the
repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.
Lubricant Article number
Molycote 1000 (molybdenum disulphide grease) 11712016-618
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.

8.4 Screw joints
Continued
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws. Any special torque
specified in the repair, maintenance or installation procedure overrides the standard
torque!
Oil-lubricated screws with allen head screws

oil-lubricated screws with allen head screws. Any special torque specified in the
repair, maintenance or installation procedure overrides the standard torque!
Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670
M24 680 960 1150
Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws. Any special torque specified in the repair, maintenance or installation
procedure overrides the standard torque!
Dimension Tightening torque (Nm) Tightening torque (Nm)
Class 10.9, lubricated i Class 12.9, lubricated i
M8 28 35
M10 55 70
M12 96 120
M16 235 280
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

8.4 Screw joints
Continued
Water and air connectors

water and air connectors when one or both connectors are made of brass. Any
special torque specified in the repair, maintenance or installation procedure
overrides the standard torque!
Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm -
Nominal Min. Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

8.5 Weight specifications
8.5 Weight specifications
Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. 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.
Example
Following is an example of a weight specification in a procedure:
Action Note
CAUTION
The robot weighs 440 kg.

All lifting accessories used must be sized accord-
ingly!

8.6 Standard tools
8.6 Standard tools
General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.
Contents, standard toolkit
Qty Tool
1 Ring-open-end spanner 8-19 mm
1 Socket head cap 2.5-17 mm
1 Torx socket no: 20-60
1 Torque wrench 10-100 Nm
1 Small screwdriver
1 Plastic mallet
1 Ratchet head for torque wrench 1/2"
1 Socket head cap no: 5, socket 1/2" bit L 20 mm
1 Small cutting plier
1 T-handle with ball head

8.7 Special tools
8.7 Special tools
General
All service instructions contain lists of tools required to perform the specified
activity. The required tools are a sum of standard tools, defined in the section
Standard tools on page 385, and of special tools, listed directly in the instructions
and also gathered in this section.
Measuring tools, play

The tools listed for measuring the play are used after service work on axes 5 and
6.
Description Robot variant Art. no.
Measuring tool, play IRB 4600 - 60/2.05, -45/2.05, -40/2.55 3HAB1611-6
Measuring tool, play IRB 4600 - 20/2.50 3HAB6337-1
Special tools
The following table specifies the special tools required during several of the service
procedures. The tools may be ordered separately and are also specified directly
in concerned instructions in the product manual.
Description Qty Art. no.
Guide pins, removal/refitting 2 pcs -
of axis 1 gearbox
Guide pins, removal/refitting 2 pcs -
of axis 3 gearbox
Oil change equipment

The following table specifies the oil change equipment. The tool is specified directly
in concerned instructions in the product manual.
Description Included parts Art. no.
Oil change equipment • vacuum pump with 3HAC021745-001
regulator, hose and
coupling
• couplings and adapters
• pump (manual) with
hose and coupling
• graduated measuring
glass
• oil gun
• user instructions.
Calibration equipment, Levelmeter (alternative method)

The following table specifies the calibration equipment required when calibrating
the robot with the alternative method, Levelmeter Calibration.
Description Art. no. Note
Angle bracket 68080011-LP
Calibration bracket 3HAC13908-9

8.7 Special tools
Continued

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
Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating
the robot with the Calibration Pendulum method.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.
Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.
If no data is found related to standard calibration, Calibration Pendulum is used
as default.
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating
manual.
Calibration equipment, Axis Calibration

The following table specifies the calibration equipment needed when calibrating
the robot with the Axis Calibration method.
The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.
Always use the same calibration method as used at the factory.
Information about valid calibration method is found on the calibration label or in
the calibration menu on the FlexPendant.
If no data is found related to standard calibration, Calibration Pendulum is used
as default.
Calibration tool box, Axis Cal- 3HAC062326- Delivered as a set of calibration tools.
ibration 001 Required if Axis Calibration is the valid
calibration method for the robot.
Contains a removal tool for removing
special protection plugs on the turning
disk.
Turning tool for suspended mounting

The following table specifies the lifting tool required when fitting the robot in a
suspended position.
Turning tool (includes lifting instruction) 3HAC034766-001 Valid for other designs
than type C.

8.7 Special tools
Continued

Turning tool (includes lifting instruction 3HAC048502-001 Valid for all types
3HAC051688-001)
Lifting accessories
This table specifies the lifting accessories required during several of the service
procedures. The lifting accessories can be ordered separately and are also specified
directly in concerned instructions.
Description Qty 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

8.8 Lifting accessories and lifting instructions
8.8 Lifting accessories and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting accessories,
which are specified in each procedure.
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.

9 Spare part lists
9.1 Spare part lists and illustrations
9 Spare part lists

9.1 Spare part lists and illustrations
Location
Spare parts and exploded views are not included in the manual but delivered as
a separate document on the documentation DVD.

10 Circuit diagram
10.1 Circuit diagrams
10 Circuit diagram
Overview
The circuit diagrams are not included in this manual, but delivered as separate
documents on the documentation DVD. See the article numbers in the tables below.
Controllers
Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Compact 3HAC049406-003
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 3HAC024120-004
Circuit diagram - Spot welding cabinet 3HAC057185-001
Robots

Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 1600/1660 3HAC021351-003
Circuit diagram - IRB 4400/4450S 3HAC9821-1
Circuit diagram - IRB 6400RF 3HAC8935-1
Circuit diagram - IRB 6600 type A 3HAC13347-1
3HAC025744-001
Circuit diagram - IRB 6600 type B 3HAC13347-1
3HAC025744-001

10 Circuit diagram
Continued

Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001
3HAC029940-001
3HAC025744-001
Circuit diagram - IRB 910SC 3HAC056159-002

Index
Index D
danger levels, 44
direction of axes, 348
A
Absolute Accuracy, calibration, 343 E
aluminum enabling device, 41
disposal, 372 environmental information, 372
ambient humidity ESD
operation, 67 damage elimination, 57
storage, 66 sensitive equipment, 57
ambient temperature wrist strap connection point, 57
operation, 67 expansion container
storage, 66 installing, 109
assembly instructions, 63 expected life, 125
Axis Calibration, 353
calibration tool F
article number, 355, 360 fence dimensions, 36
examining, 355 fire extinguishing, 37
installation position, 357 FlexPendant
overview of method, 353 jogging to calibration position, 369
procedure on FlexPendant, 360 MoveAbsJ instruction, 369
protective cover and protection plug, 357, 360 updating revolution counters, 350
foundation
B requirements, 66
batteries
disposal, 372 G
handling, 59 gearboxes
battery pack location of, 161
replacing, interval, 124 Gravity Alpha, 85
brakes Gravity Beta, 84
testing function, 39 grease
disposal, 372
C
cabinet lock, 27, 34 H
cabling, robot, 114 hanging
cabling between robot and controller, 114 installed hanging, 27
calibrating hazardous material, 372
robot, 353 height
roughly, 349 installed at a height, 27
calibrating robot, 353 hold-to-run, 41
calibration hot components
Absolute Accuracy type, 342 risk, 27
rough, 349 humidity
standard type, 342 operation, 67
verification, 368 storage, 66
when to calibrate, 344
calibration, Absolute Accuracy, 343 I
calibration manuals, 343 instructions for assembly, 63
calibration marks, 345 intervals for maintenance, 123
calibration position
jogging to, 369 L
scales, 345 labels
calibration scales, 345 robot, 46
CalibWare, 342 leak-down test, 204
carbon dioxide extinguisher, 37 lifting
cast iron accessory, 76
disposal, 372 lifting accessory, 384
cleaning, 200 Lithium
climbing on robot, 27 disposal, 372
Cold environments, 113 loads on foundation, 65
connecting the robot and controller, cabling, 114 lubrication
connection amount in gearboxes, 160
external safety devices, 23 type of lubrication, 160
copper
disposal, 372 M
main power
switching off, 55

Index
main switch introduction, 21

controller cabinet, 55 moving robots, 52
control module, 56 reduced speed function, 40
drive module, 56 release robot arm, 38
maintenance schedule, 123 robot, 23
MoveAbsJ instruction, 369 service, 23
signal lamp, 43
N signals, 44
negative directions, axes, 348 signals in manual, 44
neodymium symbols, 44
disposal, 372 symbols on robot, 46
NiCad test run, 53
disposal, 372 working range, 42
nodular iron wrist strap, 57
disposal, 372 safety risk
electric parts, 34
O hot parts, 29
oil hydraulic system, 31
amount in gearboxes, 160 installation, 26
disposal, 372 oil change, 60
type of oil, 160 operational disturbance, 33
oil change pneumatic system, 31
axis 1, floor mounted robots, 162 pressure relief valve, 32
axis 1, suspended robots, 168 service work, 26
axis 2, 174 tools, 30
axis 3, 178 voltage, 34
axis 4, 185 work pieces, 30
axis 5, 189 safety signals
axis 6, 189 in manual, 44
safety risks, 60 safety standards, 378
operating conditions, 67 safety zones, 27
options scales on robot, 345
expansion container, 109 schedule for maintenance, 123
screw joints, 381
P signal lamp, 43
pedestal signals
installed on pedestal, 27 safety, 44
plastic special tools, 386
disposal, 372 speed
positive directions, axes, 348 adjusting, 113
product standards, 378 stability, 72
protection classes, 67 standards, 378
protection type, 67 ANSI, 379
protective equipment, 26 CAN, 379
protective wear, 26 EN, 378
R EN IEC, 378
requirements on foundation, 66 EN ISO, 378
responsibility and validity, 23 start of robot in cold environments, 113
revolution counters steel
storing on FlexPendant, 350 disposal, 372
updating, 349 storage conditions, 66
risk of tipping, 72 suspended mounting, 84
robot symbols
labels, 46 safety, 44
protection class, 67 synchronization position, 349
protection types, 67 sync marks, 345
symbols, 46 system parameter
rubber Gravity Alpha, 85
disposal, 372 Gravity Beta, 84
S T
safety temperatures
brake testing, 39 operation, 67
ESD, 57 storage, 66
fence dimensions, 36 testing
fire extinguishing, 37 brakes, 39
three-position enabling device, 41

Index
tilted mounting, 84 V
tools validity and responsibility, 23
Axis Calibration, 387 velocity
calibration equipment, Levelmeter, 386 adjusting, 113
Calibration Pendulum, 387 verifying calibration, 368
for service, 386
torques on foundation, 65 W
turning weight, 64
accessory, 76 robot, 74, 82, 253–254, 256, 258, 262, 267, 271, 273,
278, 280, 291, 293, 320, 322, 328, 330, 337–338, 384
U
updating revolution counters, 349 Z
zero position
checking, 369

3HAC033453-001, Rev Q, en
ABB AB, Robotics
Robotics and Motion
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics

Robotics and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Engineering (Shanghai) Ltd.

Robotics and Motion
No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
ABB Inc.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
www.abb.com/robotics

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ROBOTICS

Document ID: 3HAC033453-001

© Copyright 2009-2017 ABB. All rights reserved.

© Copyright 2009-2017 ABB. All rights reserved.

2 Installation and commissioning 63

Product manual - IRB 4600 5

2.4.2 Mechanically restricting the working range of axis 1 ...................................... 98

6 Product manual - IRB 4600

4.4.2 Replacing complete tubular shaft unit ......................................................... 269

7 Robot description 375

8 Reference information 377

9 Spare part lists 391

Product manual - IRB 4600 7

10 Circuit diagram 393

8 Product manual - IRB 4600

Overview of this manual

Who should read this manual?

Continues on next page

Continues on next page

Continues on next page

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16 Product manual - IRB 4600

Product documentation, IRC5

Technical reference manuals

Continues on next page

18 Product manual - IRB 4600

How to read the product manual

References to required equipment

Product manual - IRB 4600 19

Product manual - IRB 4600 21

1.2 General safety information

1.2.1 Introduction to general safety information

22 Product manual - IRB 4600

1.2.2 Safety in the robot system

Validity and responsibility

Connection of external safety devices

Type of information Detailed in document Section

Continues on next page

Type of information Detailed in document Section

24 Product manual - IRB 4600

1.2.3 Protective stop and emergency stop

Product manual - IRB 4600 25

1.2.4 Safety risks

1.2.4.1 Safety risks during installation and service work on manipulators

General risks during installation and service

Spare parts and special equipment

Personal protective equipment

Nation/region specific regulations

Continues on next page

Non-voltage related risks

To be observed by the supplier of the complete system

Safety risk Description

Motors and gearboxes are HOT after running

Continues on next page

Safety risk Description

Take any necessary measures to ensure that