3hac033453 PM Irb 4600-En Revad

ROBOTICS
Product manual
IRB 4600
Trace back information:
Workspace 23D version a12
Checked in 2023-12-06
Skribenta version 5.5.019
Product manual
IRB 4600 - 60/2.05
IRB 4600 - 45/2.05
IRB 4600 - 40/2.55
IRB 4600 - 20/2.50
IRC5, OmniCore
Document ID: 3HAC033453-001

Revision: AD
© Copyright 2009-2023 ABB. All rights reserved.

Specifications subject to change without notice.
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, damage to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

Table of contents
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 18
How to read the product manual ...................................................................................................... 20
1 Safety 21
1.1 Safety information ............................................................................................. 21
1.1.1 Limitation of liability ................................................................................. 21
1.1.2 Requirements on personnel ...................................................................... 22
1.2 Safety signals and symbols ................................................................................. 23
1.2.1 Safety signals in the manual ...................................................................... 23
1.2.2 Safety symbols on manipulator labels ......................................................... 25
1.3 Robot stopping functions .................................................................................... 31
1.4 Safety during installation and commissioning ......................................................... 32
1.5 Safety during operation ...................................................................................... 35
1.6 Safety during maintenance and repair ................................................................... 36
1.6.1 Safety during maintenance and repair ......................................................... 36
1.6.2 Emergency release of the robot axes .......................................................... 39
1.6.3 Brake testing .......................................................................................... 40
1.7 Safety during troubleshooting .............................................................................. 41
1.8 Safety during decommissioning ........................................................................... 42
2 Installation and commissioning 43

2.1 Introduction to installation and commissioning ....................................................... 43
2.2 Unpacking ....................................................................................................... 44
2.2.1 Pre-installation procedure ......................................................................... 44
2.2.2 Technical data ........................................................................................ 45
2.2.3 Working range and type of motion .............................................................. 49
2.2.4 Risk of tipping/stability ............................................................................. 54
2.2.5 The unit is sensitive to ESD ....................................................................... 56
2.3 On-site installation ............................................................................................ 57
2.3.1 Minimum required free space above the robot .............................................. 57
2.3.2 Lifting robot with roundslings .................................................................... 59
2.3.3 Lifting and turning a suspended mounted robot ............................................ 62
2.3.4 Manually releasing the brakes ................................................................... 63
2.3.5 Orienting and securing the robot ................................................................ 66
2.3.6 Setting the system parameters for a suspended or tilted robot ......................... 70
2.3.7 Fitting equipment on robot ........................................................................ 74
2.3.8 Loads fitted to the robot, stopping time and braking distances ......................... 81
2.3.9 Installation of signal lamp (option) .............................................................. 82
2.4 Restricting the working range .............................................................................. 83
2.4.1 Axes with restricted working range ............................................................. 83
2.4.2 Mechanically restricting the working range of axis 1 ...................................... 84
2.5 Installing options ............................................................................................... 87
2.5.1 Installation of cooling fan for motors (option) ................................................ 87
2.5.2 Installation of Foundry Plus Cable guard (option) .......................................... 94
2.5.3 Installing an expansion container ............................................................... 95
2.6 Robot in hot environments .................................................................................. 100
2.6.1 Start of robot in hot environments .............................................................. 100
2.7 Robot in cold environments ................................................................................. 101
2.7.1 Start of robot in cold environments ............................................................ 101
2.8 Electrical connections ........................................................................................ 102
2.8.1 Robot cabling and connection points .......................................................... 102
2.8.2 Customer connection on robot ................................................................... 105
2.9 Test run after installation, maintenance, or repair .................................................... 110
Product manual - IRB 4600 5

3HAC033453-001 Revision: AD
Table of contents
3 Maintenance 111
3.1 Introduction ...................................................................................................... 111
3.2 Maintenance schedule ....................................................................................... 112
3.2.1 Specification of maintenance intervals ........................................................ 112
3.2.2 Maintenance schedule ............................................................................. 113
3.2.3 Expected component life ......................................................................... 115
3.3 Inspection activities ........................................................................................... 116
3.3.1 Inspecting oil level, axis 1 gearbox ............................................................. 116
3.3.2 Inspecting the oil level, axis 2 gearbox ........................................................ 123
3.3.5 Inspecting oil level, gearbox axes 5 - 6 ........................................................ 131
3.3.6 Inspecting the cable harness ..................................................................... 136
3.3.7 Inspecting information labels ..................................................................... 140
3.3.8 Inspecting the mechanical stop pin, axis 1 ................................................... 144
3.3.9 Inspecting additional mechanical stops ....................................................... 147
3.3.10 Inspecting dampers ................................................................................. 149
3.3.11 Inspecting the pressure relief valve ............................................................ 151
3.3.12 Inspecting Signal lamp (option) .................................................................. 153
3.4 Replacement activities ....................................................................................... 155
3.4.1 Type of lubrication in gearboxes ................................................................ 155
3.4.2 Changing the oil, axis-1 gearbox on floor mounted robots ............................... 157
3.4.3 Changing the oil, axis-1 gearbox on suspended robots ................................... 162
3.4.4 Changing the oil, axis-2 gearbox ................................................................ 168
3.4.7 Changing oil, axes-5 and -6 gearboxes ........................................................ 183
3.4.8 Replacing SMB battery ............................................................................. 189
3.4.9 Replacing cable strap on the protection tubes .............................................. 194
3.5 Cleaning activities ............................................................................................. 197
3.5.1 Cleaning the IRB 4600 .............................................................................. 197
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 sealings .............................................................. 207
4.2.4 Cut the paint or surface on the robot before replacing parts ............................ 211
4.2.5 The brake release buttons may be jammed after service work ......................... 213
4.3 Complete robot ................................................................................................. 214
4.3.1 Removing the complete cable harness ........................................................ 214
4.3.2 Refitting the complete cable harness .......................................................... 229
4.3.3 Replacing SMB unit ................................................................................. 248
4.3.4 Replacing the brake release board ............................................................. 255
4.3.5 Replacing the base .................................................................................. 260
4.4 Upper arm ....................................................................................................... 272
4.4.1 Replacing the complete upper arm ............................................................. 272
4.4.2 Replacing complete tubular shaft unit ......................................................... 285
4.4.3 Replacing wrist unit ................................................................................. 292
4.4.4 Measuring the play, axis 5 ......................................................................... 300
4.4.5 Measuring the play, axis 6 ......................................................................... 303
4.5 Lower arm ....................................................................................................... 306
4.5.1 Replacing the lower arm ........................................................................... 306
4.6 Frame and base ................................................................................................ 317
4.6.1 Replacing stop pin axis 1 .......................................................................... 317
4.7 Motors ............................................................................................................ 320
4.7.1 Removing motors .................................................................................... 320
6 Product manual - IRB 4600

Table of contents
4.7.2 Refitting motors ...................................................................................... 329

4.7.3 Adjusting the play of axis 4, 5 and 6 motors ................................................. 339
4.8 Gearboxes ....................................................................................................... 340
4.8.1 Replacing gearbox axis 1 .......................................................................... 340
5 Calibration 373
5.1 Introduction to calibration ................................................................................... 373
5.1.1 Introduction and calibration terminology ...................................................... 373
5.1.2 Calibration methods ................................................................................. 374
5.1.3 When to calibrate ................................................................................... 377
5.2 Synchronization marks and axis movement directions ............................................. 378
5.2.1 Synchronization marks and synchronization position for axes ......................... 378
5.2.2 Calibration movement directions for all axes ................................................ 381
5.3 Updating revolution counters ............................................................................... 382
5.3.1 Updating revolution counters on IRC5 robots ............................................... 382
5.3.2 Updating revolution counters on OmniCore robots ........................................ 386
5.4 Calibrating with Axis Calibration method ............................................................... 388
5.4.1 Description of Axis Calibration .................................................................. 388
5.4.2 Calibration tools for Axis Calibration ........................................................... 391
5.4.3 Installation locations for the calibration tools ............................................... 393
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 396
5.4.5 Reference calibration ............................................................................... 401
5.5 Calibrating with Calibration Pendulum method ....................................................... 403
5.6 Calibrating with Wrist Optimization method ........................................................... 404
5.7 Verifying the calibration ...................................................................................... 406
5.8 Checking the synchronization position .................................................................. 407
6 Decommissioning 409
6.1 Introduction to decommissioning ......................................................................... 409
6.2 Environmental information .................................................................................. 410
6.3 Scrapping of robot ............................................................................................. 412
7 Robot description 413

7.1 Manipulator types and variants ............................................................................ 413
7.2 Type C of IRB 4600 ............................................................................................ 414
7.3 Type D of IRB 4600 ............................................................................................ 415
8 Reference information 417

8.1 Introduction ...................................................................................................... 417
8.2 Applicable standards ......................................................................................... 418
8.3 Unit conversion ................................................................................................. 419
8.4 Screw joints .................................................................................................... 420
8.5 Weight specifications ......................................................................................... 423
8.6 Standard tools .................................................................................................. 424
8.7 Special tools .................................................................................................... 425
8.8 Lifting accessories and lifting instructions .............................................................. 428
9 Spare part lists 429

9.1 Spare part lists and illustrations ........................................................................... 429
10 Circuit diagram 431

10.1 Circuit diagrams ................................................................................................ 431
Index 433

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Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical installation of the IRB 4600
• maintenance of the IRB 4600
• mechanical and electrical repair of the IRB 4600
The robot described in this manual has the following protection types:
• Standard
• Foundry Plus
• Clean Room
This manual describes the manipulator using either the IRC5 or the OmniCore
controller.
Product manual scope

The manual covers all variants and designs of the IRB 4600. Some variants and
designs may have been removed from the business offer and are no longer available
for purchase.
Usage
This manual should be used during:
• installation and commissioning, from lifting the product to its work site and
securing it to the foundation, to making it ready for operation
• maintenance work
• repair work
• decommissioning work
Note
It is the responsibility of the integrator to conduct a risk assessment of the final

application.
It is the responsibility of the integrator to provide safety and user guides for the
robot system.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Continues on next page

Continued
• be trained to respond to emergencies or abnormal situations.
References
General
Reference Document ID
Product manual, spare parts - IRB 4600 3HAC049108-001
Product manual - IRB 4600 Foundry Prime 3HAC040585-001
Circuit diagram - IRB 4600 3HAC029038-003
Technical reference manual - Lubrication in gearboxes 3HAC042927-001
Safety manual for robot - Manipulator and IRC5 or OmniCore 3HAC031045-001
controller i
Operating manual - Emergency safety information 3HAC027098-001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
OmniCore robots
Product specification - IRB 4600 3HAC080366-001
Product manual - OmniCore V400XT 3HAC081697-001
Product manual - OmniCore V250XT Type B 3HAC087112-001
Operating manual - OmniCore 3HAC065036-001
Technical reference manual - System parameters 3HAC065041-001
Application manual - Additional axes for OmniCore 3HAC082287-001
IRC5 robots
Product specification - IRB 4600 3HAC032885-001
Product manual - IRC5 3HAC021313-001
Product manual - IRC5 3HAC047136-001
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - Calibration Pendulum 3HAC16578-1
Operating manual - Service Information System 3HAC050944-001
Technical reference manual - System parameters 3HAC050948-001
Application manual - Additional axes and standalone controller 3HAC051016-001
Application manual - Electronic Position Switches 3HAC050996-001
Application manual - CalibWare Field 3HAC030421-001
Revisions
Revision Description
- First edition

Continued
A The following updates have been made in this revision:
• Added more information about working in the safeguarded space.
• Added more information about hazards with oil.
• 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 78.
• 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 375 and Calibration equipment, Levelmeter (alternative
method) on page 425.
• 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 62
added in Installation chapter.
• Section Installation of Foundry Plus Cable guard (option) on page 94
added in Installation chapter.
• New DANGER! added in section Manually releasing the brakes on
page 63.
• Restricting working range with software added in section Mechanically
restricting the working range of axis 1 on page 84.
• The sections describing Replacing motors axes 1 through 6 has been
updated. Two new sections Removing motors on page 320 and Refitting
motors on page 329 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 sec-
tions Replacing motors, axes 4, 5 and 6 and Replacing wrist unit on
page 292.
• Correction of required oil level, see Inspecting oil level, axis 1 gearbox
on page 116.
In chapter Safety :
• Updated safety signal graphics for levels Danger and Warning, see
Safety signals in the manual on page 23.
• New safety labels on the manipulators, see Safety symbols on manip-
ulator labels on page 25.
• Revised teminology: robot replaced with manipulator.

Continued
C The following updates have been made in this revision:
• Added Installing an expansion container on page 95.
• A figure showing IRB 2600 removed in section Orienting and securing
the robot on page 66.
• Section Installation of Foundry Plus Cable guard (option) on page 94
added.
• Updated the section Start of robot in cold environments on page 101.
• Interval for inspection of signal lamp added in section Maintenance
schedule on page 113.
• New design of frame added in sections Inspecting oil level, axis 1
gearbox on page 116 and Changing the oil, axis-1 gearbox on floor
mounted robots on page 157.
• Figure showing required oil level added in section Inspecting oil level,
axis 1 gearbox on page 116.
• Inspection of oil level on suspended robot updated in section Inspect-
ing oil level, axis 1 gearbox on page 116.
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 84, Inspecting the mechanical stop pin, axis
1 on page 144 and Replacing stop pin axis 1 on page 317
• All information about Foundry Prime is removed from the manual. This
manual now only contains information for a Standard IRB 4600. The
instructions 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 20.
• 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 46.
• 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 45.
• Removed Foundry from table with protection classes. See Protection
classes, robot on page 48.
• Additional information about software adjustments when suspending
robot, new section Setting the system parameters for a suspended or
tilted robot on page 70.
• Note about fan cabling added in the cable list. See Robot cabling and
connection points on page 102.
• Note about ambient temperature deleted from the maintenance
schedule. See Maintenance schedule on page 113.
• Changed information about the robot position when removing motor.
See Removing motors on page 320.
• Additional instructions for how to adjust the play of axes 4, 5 and 6
motors. See Adjusting the play of axis 4, 5 and 6 motors on page 339.
• Added step about removing/refitting axis 1 motor when replacing the
axis 1 gearbox. Also added information about guide pins. See Repla-
cing gearbox axis 1 on page 340. 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 381.
• New section about how to perform a rough calibration of each robot
axis is added, see Updating revolution counters on IRC5 robots on
page 382.
• New section about how to check the calibration position is added, see
Checking the synchronization position on page 407.
• 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 279.
• Additional information in the procedure for replacing the base with
improved lifting instruction etc., see Replacing the base on page 260.
• Changed type of oil in axes 1, 3 and 4 gearboxes. See Type of lubric-
ation in gearboxes on page 155.

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 300.
• 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 272, Replacing gearbox axis 3 on
page 363 and Replacing gearbox axis 2 on page 352.
• 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 363 and Replacing gearbox axis 2 on page 352.
• Added safety information about preventing roundslings from sliding
when lifting the upper arm tube, see Replacing complete tubular shaft
unit on page 285.
• Added information about removing painting, if any, from assembly
surfaces 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 179.
• Added information about o-ring and made other minor approvements
to the instruction for replacing wrist unit, see Replacing wrist unit on
page 292.
• Added information about disconnecting the battery cable when remov-
ing the cable harness, see Removing the complete cable harness on
page 214.
• Added a funnel to equipment list, see Changing the oil, axis-3 gearbox
on page 172.
• Added Profibus to the section about connections to extra equipment,
see Customer connection on robot on page 105.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 420.
• 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 162.
• Added spare part number for type B gearbox (axis 3), see Spare parts,
upper arm.
• Added information about batteries.
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 suspen-
ded robots is clarified, see Inspecting oil level, axis 1 gearbox on
page 116.
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 412.
• 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 67.
• Term "Guide sleeves" changed to "Guide bushings", see Dimension,
mounting surface and guide bushing on page 67.
• A new WARNING! is added in the section about motor replacement,
informing 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 84.
• Information about removing the mech stop bracket added in section
Axes with restricted working range on page 83.
M The following updates have been made in this revision:
• Turning disk fixture is removed from special tools for Levelmeter cal-
ibration.
• Oil levels adjusted.
• Information about grounding and bonding point added, see Robot
cabling and connection points on page 102.
N Published in release R16.2. The following updates are done in this revision:
• Corrections due to updates in terminology.
• New dimensional drawing of the turning disk added to Fitting equip-
ment on wrist and mounting flange on page 78.
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 373.
• Information about grounding point added. See Robot cabling and
connection points on page 102.
P Published in release R17.1. The following updates are done 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 done in this revision:
• Information about coupled axes in Updating revolution counters on
IRC5 robots on page 382.
• 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 proced-
ure on the FlexPendant on page 396.
• 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 101.
• 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.
R Published in release R18.1. The following updates are done in this revision:
• Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 391.
• Added sections in General procedures on page 204.
• Updated figure of axis-6 synchronization mark.
• Safety restructured.
• Added information about harness customer ethernet connection.
• New spare part numbers for Brake release board.
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference calib-
ration values.
• Information about myABB Business Portal added.
• Information about measuring the play in axis 5 and 6 updated.
• Added Nickel in Environmental information.
S Published in release R18.2. The following updates are done in this revision:
• Updates related to mechanical stop pin.
• Changed the method for replacing the axis-1 gearbox and the base.
T Published in release R18.2. The following updates are done in this revision:
• Updated references.
U Published in release 19B. The following updates are made in this revision:
• New touch up color Graphite White available. See Cut the paint or
surface on the robot before replacing parts on page 211.
• New article numbers for manipulator cables in section Robot cabling
and connection points on page 102.
• Levelmeter 2000 kit (6369901-347) no longer available.
• Added spare parts for wrist and sealing for IRB 4600 -20/2.50. See
Replacing wrist unit on page 292.
•
• Added a note regarding usage of an angled ethernet connection, see
Customer connection on robot on page 105.
V Published in release 19D. The following updates are made in this revision:
• Note added about the need to calibrate if the robot is other than floor
mounted. See When to calibrate on page 377.

Continued
W Published in release 20B. The following updates are made in this revision:
• Clarified and added information in mounting instructions for rotating
sealings, see Mounting instructions for sealings on page 207.
• Clarified text about position of robot and added table with dependen-
cies between axes during Axis Calibration.
• Article number of Calibration tool box, Axis Calibration is changed
from 3HAC062326-001 to 3HAC074119-001.
• Replaced article number and name of grease, previously 3HAB3537-
1.
• Added information about Wrist Optimization in calibration chapter.
X Published in release 20C. The following updates are made in this revision:
• Added note about differences in type of oil pre-filled in axis-4 gear
compared to recommended oil for field maintenance.
• Updated section about customer connections in regard to Ethernet
etc. See Customer connection on robot on page 105.
Y Published in release 21A. The following updates are made in this revision:
• Note regarding maximum leakage current for attached equipment.
See Customer connection on robot on page 105.
• Description for new Type D with alternative motor added to Type D of
IRB 4600 on page 415.
• "Type C" is now "Type C and Type D" through out the complete
manual.
Z Published in release 21B. The following updates are made in this revision:
• New cable bracket. See Location of axis-3, axis-4, axis-5 and axis-6
motors on page 321.
• Information regarding documentation of Installation of Foundry Plus
Cable guard (option no. 908-1) is changed since DVDs are removed.
See Installation of Foundry Plus Cable guard (option) on page 94.
• Text regarding fastener quality is updated, see Fastener quality on
page 80.
AA Published in release 21D. The following updates are made in this revision:
• Added information for the OmniCore robot controller.
AB Published in release 22B. The following updates are done in this revision:
• Updated information about Gleitmo treated screws, see Screw joints
on page 420.
• Updated manipulator weight.
• Corrected manipulator variant designations in section Installing an
expansion container on page 95.
AC Published in release 23C. The following updates are done in this revision:
• Added protection type Clean Room for variant IRB 4600 - 60/2.05 and
IRB 4600 - 40/2.55.
• Added axis positions for most stable transport position and removed
information about shipping position.
AD Published in release 23D. The following updates are done in this revision:
• Added illustrations to the section Cleaning.
• Added support for OmniCore V400XT.

Product documentation
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.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Product manuals
Manipulators, controllers, DressPack, 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.
• Troubleshooting.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals

The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application 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, software).
• How to install included or required hardware.
• How to use the application.

Continued
• 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.

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.

1 Safety
1.1.1 Limitation of liability
1 Safety
1.1 Safety information
1.1.1 Limitation of liability
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.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed as
intended.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
Spare parts and equipment

ABB supplies original spare parts and equipment which have been tested and
approved for their intended use. The installation and/or use of non-original spare
parts and equipment can negatively affect the safety, function, performance, and
structural properties of the robot. ABB is not liable for damages caused by the use
of non-original spare parts and equipment.

1 Safety
1.1.2 Requirements on personnel
1.1.2 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.
Personal protective equipment

Use personal protective equipment, as stated in the instructions.

1 Safety
1.2.1 Safety signals in the manual
1.2 Safety signals and symbols
Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
WARNING Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in serious
injury.
ELECTRICAL Signal word used to indicate a potentially hazardous

SHOCK situation related to electrical hazards which, if not
avoided, could result in serious injury.
CAUTION Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in slight
injury.
ELECTROSTATIC Signal word used to indicate a potentially hazardous

DISCHARGE (ESD) situation which, if not avoided, could result in severe
damage to the product.
NOTE Signal word used to indicate important facts and

conditions.

1 Safety
Continued
Symbol Designation Significance

TIP Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.

1 Safety
1.2.2 Safety symbols on manipulator labels
Introduction to symbols
This section describes safety symbols used on labels (stickers) on the manipulator.
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 symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important 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 25.
The information labels can contain information in text.
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 disassembly, 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
Adjustable 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
1.3 Robot stopping functions
1.3 Robot stopping functions
Protective stop and emergency stop

The protective stops and emergency stops are described in the product manual
for the controller.
For more information see:
• Product manual - OmniCore V250XT Type A
• Product manual - OmniCore V250XT Type B
• Product manual - OmniCore V400XT
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted Controller

1 Safety
1.4 Safety during installation and commissioning
National or regional regulations

The integrator of the robot system is responsible for the safety of the robot system.
The integrator is responsible that the robot system is designed and installed in
accordance with the safety requirements set forth in the applicable national and
regional standards and regulations.
The integrator of the robot system is required to perform a risk assessment.
Layout
The robot integrated to a robot system shall be designed to allow safe access to
all spaces during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing
the working space.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand
the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum
speed.
• The maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed
in the section Robot motion in the product specification for the respective
manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall be considered.
Hazards due to noise emission from the robot needs to be considered.
Consider hazards from other equipment in the robot system, for example, that
guards remain active until identified hazards are reduced to an acceptable level.
Allergenic material
See Environmental information on page 410 for specification of allergenic materials
in the product, if any.
Securing the robot to the foundation

The robot must be properly fixed to its foundation/support, as described in the
respective product manual.
When the robot is installed at a height, hanging, or other than mounted directly on
the floor, there will be additional hazards.

1 Safety
Continued
Using lifting accessories and other external equipment

Ensure that all equipment used during installation, service and all handling of the
robot are in correct condition for the intended use.
Electrical safety
Incoming mains must be installed to fulfill national regulations.
The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.
Wherever possible, power on/off or rebooting the robot controller shall be performed
with all persons outside the safeguarded space.
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.
Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.
Other hazards
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
The risk assessment should also consider other hazards arising from the
application, such as, but not limited to:
• Water
• Compressed air
• Hydraulics
End-effector hazards require particular attention for applications which involve
close human collaboration with the robot.

1 Safety
Continued
Pressure relief valves

The pressure relief valve prevents too much air pressure being built up inside the
robot. The air pressure must not exceed the rated limit for the manipulator, or there
is a risk of personal injury and mechanical damage.
Pressure relief valves must be kept clean.
Pneumatic or hydraulic related hazards
Note
The pressure in the complete pneumatic or hydraulic systems must be released

before service and maintenance.
All components in the robot system that remain pressurized after switching off
the power to the robot must be marked with clearly visible drain facilities and a
warning sign that indicates the hazard of stored energy.
Loss of pressure in the robot system may cause parts or objects to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
All pipes, hoses, and connections have to be inspected regularly for leaks and
damage. Damage must be repaired immediately.
Verify the safety functions

Before the robot system is put into operation, verify that the safety functions are
working as intended and that any remaining hazards identified in the risk
assessment are mitigated to an acceptable level.

1 Safety
1.5 Safety during operation
1.5 Safety during operation
Automatic operation
Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.
Unexpected movement of robot arm
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
WARNING
equipment.

1 Safety
1.6.1 Safety during maintenance and repair
1.6 Safety during maintenance and repair
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Hazards due to stored mechanical energy in the manipulator for the purpose of
counterbalancing axes must be considered before maintenance or repair.
Never use the robot as a ladder, which means, do not climb on the controller,
manipulator, including motors, or other parts. There are hazards of slipping and
falling. The robot might be damaged.
Make sure that there are no tools, loose screws, turnings, or other unexpected
parts remaining after maintenance or repair work.
When the work is completed, verify that the safety functions are working as
intended.
Hot surfaces
Surfaces can be hot after running the robot, and touching these may result in burns.
Allow the surfaces to cool down before maintenance or repair.
Allergic reaction
Warning Description Elimination/Action

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
Allergic reaction
Gearbox lubricants (oil or grease)

When handling oil, grease, or other chemical substances the safety information of
the respective manufacturer must be observed.
Note
Take special care when handling hot lubricants.

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.
Hot oil or grease

1 Safety
Continued

When working with lubricants Make sure that protective gear
there is a risk of an allergic reac- like goggles and gloves are al-
tion. ways worn.
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
opening.
Possible pressure
build-up in gearbox
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
• 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
for the product.
Do not mix types of oil
Oil residues might be present in Make sure that protective gear
a drained gearbox and spilled like goggles/protective visor,
when separating a motor and gloves and arm protection are
gearbox during repair. always worn during this activity.
Put oil absorbent cloth or paper
Oil residues
at appropriate locations to catch
any oil residues.
Warm oil drains quicker than Run the robot before changing
cold oil. the gearbox oil, if possible.
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
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

1 Safety
Continued

For lifetime reasons always drain
as much oil as possible from the
gearbox. The magnetic oil plugs
will gather residual metal chips.
Contaminated oil in
gearboxes
Hazards related to batteries

Under rated conditions, the electrode materials and liquid electrolyte in the batteries
are sealed and not exposed to the outside.
There is a hazard in case of abuse (mechanical, thermal, electrical) which leads
to the activation of safety valves and/or the rupture of the battery container. As a
result under certain circumstances, electrolyte leakage, electrode materials reaction
with moisture/water or battery vent/explosion/fire may follow.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
Operating temperatures are listed in Operating conditions, robot on page 48.
See safety instructions for the batteries in Material/product safety data
sheet - Battery pack (3HAC043118-001).
WARNING
WARNING
equipment.
Related information
See also the safety information related to installation and operation.

1 Safety
1.6.2 Emergency release of the robot axes
1.6.2 Emergency release of the robot axes
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 described in the section:
• Manually releasing the brakes on page 63.
The robot 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 manipulator does
not result in additional hazards, for example, even more severe injuries on a trapped
person.
DANGER
When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways.
Make sure no personnel is near or beneath the robot.

1 Safety
1.6.3 Brake testing
1.6.3 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 axis to a position where the combined weight of the manipulator
and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the manipulator does not change position as the motors are switched off,
then the brake function is adequate.
Note
It is recommended to run the service routine BrakeCheck as part of the regular

maintenance, see the operating manual for the robot controller.
For robots with the option SafeMove, the Cyclic Brake Check routine is
recommended. See the manual for SafeMove in References on page 10.

1 Safety
1.7 Safety during troubleshooting
1.7 Safety during troubleshooting
General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.
DANGER
Troubleshooting on the controller while powered on must be performed by

personnel trained by ABB or by ABB field engineers.
A risk assessment must be done to address both robot and robot system specific
hazards.
WARNING
WARNING
equipment.
Related information
See also the safety information related to installation, operation, maintenance, and
repair.

1 Safety
1.8 Safety during decommissioning
1.8 Safety during decommissioning
General
See section Decommissioning on page 409.
If the robot is decommissioned for storage, take extra precaution to reset safety
devices to delivery status.
WARNING
WARNING
equipment.

2 Installation and commissioning
2.1 Introduction to installation and commissioning

2.1 Introduction to installation and commissioning
General
This chapter contains assembly instructions and information for installing the IRB
4600 at the working site.
See also the product manual for the robot controller.
The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.
The technical data is detailed in section Technical data on page 45.
Safety information
Before any installation work is commenced, all safety information must be 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
Always connect the IRB 4600 and the robot to protective earth and residual
current device (RCD) before connecting to power and starting any installation
work.

2.2.1 Pre-installation procedure
2.2 Unpacking
2.2.1 Pre-installation procedure
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 45
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 47
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 48
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 46
• Protection classes, robot on page 48
• Requirements, foundation on page 47
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 54
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 57
11 Install required equipment, if any.
• Installation of signal lamp (option) on page 82

2.2.2 Technical data
Weight, robot
The table shows the weight of the robot.
Robot model Weight
IRB 4600 465 kg
Note
The weight does not include tools and other equipment fitted on the robot.
Mounting positions
The table shows valid mounting options for the manipulator.
Mounting option Installation angle Note
Floor mounted 0°
Suspended 180°
Tilted 0-15° Contact ABB for further in-
formation about acceptable
loads.
Note
The actual mounting angle must always be configured in the system parameters,
otherwise the performance and lifetime is affected. See Setting the system
parameters for a suspended or tilted robot on page 70.

Continued
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!
WARNING
The robot installation is restricted to the mounting options given in following load
table(s).
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.
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 the application manual of the
time to have a controller software, section Motion Process
lower resonance Mode.
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 frequency. 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
Maximum ambient humidity 95% at constant temperature
(gaseous only)

Continued
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 i
Manipulator, protection type Standard IP 67
Manipulator, protection type Foundry Plus IP 67
Manipulator, protection type Clean Room ISO5 ii
i According to IEC 60529.
ii Protection type Clean Room is only valid for variant IRB 4600 - 60/2.05 and IRB 4600 - 40/2.55.
CAUTION
It is recommended to take the maintenance and repair work out of the clean room
environment for Clean Room variants.
The maintenance and repair work may bring up particles and cause pollution
during the work. Please contact with ABB service team in advance.
Note
Always remember to reinstall the protection plugs back to the robot after any
maintenance or repair work for the Clean Room variants.

2.2.3 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 for a floor mounted robot.
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 for a suspended mounted
robot.
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

Continued
Protection type, Clean Room
+165°
A
B
-165°
xx2300001188
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°
±165° (Clean Room)
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°

2.2.4 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 transportation position is the most stable position.
Do not change the robot position before securing it to the foundation!
Transportation position
This figure shows the robot in its 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
Axis number Angle of axis

Axis 1 0°
Axis 2 -45°
Axis 3 +75°
Axis 4 0°
Axis 5 0°

Continued
Axis number Angle of axis

Axis 6 0°
Note
The robot might be positioned in a different position at delivery, due to actual

configurations and options (for example DressPack).
WARNING
The robot will be mechanically unstable if not properly secured to the foundation.

2.2.5 The unit is sensitive to ESD
2.2.5 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.
Safe handling
Use one of the following alternatives:
• Use a wrist strap.
Wrist straps must be tested frequently to ensure that they are not damaged
and are operating correctly.
• Use an ESD protective floor mat.
The mat must be grounded through a current-limiting resistor.
• Use a dissipative table mat.
The mat should provide a controlled discharge of static voltages and must
be grounded.

2.3.1 Minimum required free space above the robot
2.3 On-site installation
Service activities require free space above the robot

Consider the need of sufficient free space above the robot during the maintenance
and repair work for Clean Room variants.

Continued
Minimum dimension of free space

A minimum dimension of free space for lifting or moving the robot is recommended.
80
0m
m
m m
00
14
1700mm
xx2300001212
Note
If any equipment or device are used when moving or lifting the robot, this may
increase the minimum dimension of free space. Please take their size into
consideration when prepare the free space for moving or lifting the robot.

2.3.2 Lifting robot with roundslings
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 62.
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 465 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 54
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 59
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 59
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 59

2.3.3 Lifting and turning a suspended mounted robot
2.3.3 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 425. Any additional equipment required is specified in the instruction for the
lifting accessory. Contact ABB for more information.
Note
Suspended mounting way is not available for the variants with protection type
Clean Room.
How to lift and turn the robot into position for tilted position: Contact ABB for more
information.
Illustration
xx1500002116

2.3.4 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 431.
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

2.3.5 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 46 and Requirements,
foundation on page 47.
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
X12 2x 1x45º
0º
Ø 35 -0.025 f7
) (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 44.
2 Prepare the installation site with attachment Hole configuration of the base is shown
holes. in the figure in:
• Hole configuration, base on
page 66
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 59
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 46.

2.3.6 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.
If the robot is mounted in any other angle than 0°, then the system parameters
that describe the mounting angle (how the robot is oriented relative to the gravity)
must be re-defined.
Note
With inverted 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 mounting positions are described in Mounting positions on page 45, and
the requirements on the foundation are described in Requirements, foundation
on page 47.
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 RobotWare

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 71.
The system parameters are described in Technical reference manual - System
parameters.
The system parameters are configured in RobotStudio or on the FlexPendant.

2.3.7 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.
Fastener quality
When fitting tools on the tool flange, only use screws with quality 12.9. For other
equipment use suitable screws and tightening torque for your application.

2.3.8 Loads fitted to the robot, stopping time and braking distances
2.3.8 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 be defined in the software.
• Operating manual - IRC5 with FlexPendant
• Operating manual - OmniCore
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 listed in References
on page 10.

2.3.9 Installation of signal lamp (option)
2.3.9 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 mechanical stop bracket if the robots full working range is from one
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 Limitation in mechanical turning range, calculated
from synchronization position
Type C and Type D ±126° to ±13.5° in steps of 22.5°
other design than Type C and Type ±129° to ±16.5° in steps of 22.5°
D
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 429. screws, washers and instruction
Attachment screw See Spare part 2 pcs/stop lug
lists on page 429. Hex socket head cap screw M12x40, quality
8.8-A3F
Washer See Spare part 2 pcs/lug
lists on page 429. 13x24x2.5
Standard toolkit Content is defined in section Standard tools

on page 424.
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 and Type D)
• -129° (other design than Type C and Type D)
B Movable mechanical stop. Limited to:
• +13.5° (Type C and Type D)
• +16.5° (other design than Type C and Type D)
C Movable mechanical stop. Limited to:
• -13.5° (Type C and Type D)
• -16.5° (other design than Type C and Type D)
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 85 for guidance.

Continued
Action Note
2 Fit the stop lugs firmly with attachment Specified in Required equipment on
screws and washers according to the figure page 84.
Additional stops on page 85. Tightening torque: 82 Nm
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.
5 Seal and paint the joints that have been
opened. Also repair possible damages of the
special Foundry Prime paint coat of the robot.
See Cut the paint or surface on the robot be-
fore replacing parts on page 211.
Note
After all repair work, wipe the robot free from

particles with spirit on a lint free cloth.

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 for IRC5 robots.
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 429
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 424.
Circuit diagram - See chapter Circuit diagram on page 431.
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 88
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 88
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
Adjustments in RobotWare
Action Note
1 Modify the settings in RobotWare to RobotWare 5: modify the option information
include the cooling fans. in System Builder (RobotStudio). Read more
about modifying the system in Operating
manual - RobotStudio.
RobotWare 6: modify the option information
using theInstallation Manager function (Ro-
botStudio). Read more about modifying the
system in Operating manual - RobotStudio.

2.5.2 Installation of Foundry Plus Cable guard (option)
2.5.2 Installation of Foundry Plus Cable guard (option)
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 for
registered users on myABB Business Portal (www.abb.com/myabb) and delivered
with the Cable guard, article number 3HAC035933-001.
xx1100000097

2.5.3 Installing an expansion container
Validity of this section

This section is only valid for other design than Type C and Type D.
Introduction to the expansion container

The expansion container is needed on suspended robots (other design than Type
C and Type D) 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. If a manipulator delivered for floor mounting is planned to be
mounted in suspended position, an expansion container must be installed.
Note
Type C and Type D are not valid for inverted mounting.

Continued
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)
Required equipment
Equipment Note
Expansion container Kit including oil.
Lifting accessory 3HAC034766-001
Lifting instruction Included with the lifting accessory.
Grease -
Locking liquid -
Loctite 2400 (or equivalent Loctite 243)
O-ring for base cover Replace if damaged.

Continued
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 62.
free for installation work.
2 Remove the cover and the o-ring from the
base.
3 Remove two existing attachment screws as
shown in the figure.
xx1500001958
The screws must be replaced with longer

screws.
4 Remove the oil plug from the base.
xx1900001818
5 Fit a plastic plug in the expansion container

drain hole.
xx1500001956
6 Fill the expansion container with oil. Oil volume: 0.4 l

Continued
Action Information
7 Apply locking liquid to the three screw holes Locking liquid: - (Loctite 2400 (or equival-
in the expansion container. ent Loctite 243)).
Knock in the VK-cover with a rubber mallet. Screws: M6x8 (3 pcs).
Secure with three screws and washers.
xx1500001957
8 Remove the plastic plug.

9 Apply some grease on the small o-ring and
place it in the recess on the expansion con-
tainer.
xx1500001956
10 Place the expansion container in the base

and place it so the drain holes match.
Tip
Turn and install the container quickly to avoid

oil spill.
11 Secure the expansion container with the at-

tachment screws and washers.
Wipe off any oil residuals before continuing. xx1500001959
Tightening torque 6 Nm.

Continued
Action Information
12 Check the o-ring used on the cover. Replace
it if damaged.
13 Refit the cover on the base with its attach-
ment screws.
xx1900001819
14 Turn the robot so it is not suspended.

15 Turn the robot to suspended position.
16 Inspect the oil level. See procedure for suspended robot, In-
specting oil level, axis 1 gearbox on
page 116.

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
Components may be hot.
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. More information about Motion Supervision is found in Technical
reference manual - System parameters.
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.
CAUTION
Connect the male and female connectors perfectly aligned horizontally to avoid
any kind of tilt or skew.
CAUTION
Verify that the serial number is according to the number(s) in the Declaration of
Incorporation (DoI).
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 103.
Fan cables (option) Handles supply to and feedback from any cooling fan on
the robot.
Specified in the table Fan cables (option) on page 104.
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 Application manual - Additional axes and standalone
controller (IRC5) or Application manual - Additional axes
for OmniCore (OmniCore), document number in References
on page 10.

Continued
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 (IRC5 con- R1.MP
drive units in the control cabinet trollers)
to the robot motors. X1 (OmniCore
controllers)
Robot cable, signals Transfers resolver data from XS2 (IRC5 con- R1.SMB
and power supply to the serial trollers)
measurement board. X2 (OmniCore
controllers)
Robot cable, power
Cable Art. no.

Robot cable, power: 7 m 3HAC026787-001
Robot cable, signals
Cable Art. no.

Robot cable signal, shielded: 7 m 3HAC068917-001
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

Continued
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
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 87.

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 can be two UTOW71210SH06 and
one UTOW71626SH06 connector on the front part of the upper arm.
Note
The maximum leakage current for attached equipment must not exceed 10mA.
The customer connections are located on the robot as shown in the figure.
Customer connections on upper arm with signal lamp

The figure shows the customer connections on the upper arm, including the optional
signal lamp that can be fitted to the arm house.
A B C D
xx2000001660
A R2.PROC1
Air M16x1.5
(24° cone sealing)
B R2.ETHERNET i
C R2.CP or R2.CBUS
D R2.CS or R2.CP/CS
E Signal lamp
- R3.H1 +, R3.H2 - (inside the arm house, not shown in figure)
i Use a straight ethernet connector. Using an angled connector causes a collision risk with R2.CP,
R2.CBUS, R2.CS or R2.CP/CS.

Continued
Customer connections base
A B C D
xx2000001636
A R1.CP/CS
B R1.PROC1 (Air M16x1.5)
C R1.ETHERNET
D R1.SMB
Customer connections base with 7th axis
A B E C D
xx2000001637
A R1.CP/CS
B R1.PROC1 (Air M16x1.5)
C R1.ETHERNET
D R1.SMB
E R2.FB7

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 diameter of the air hose: 9.5 mm.
Number of signals, customer connections option Parallel&Air (803-1):
• 23 (50V, 0.5A)
• 9 (300V, 2A). 8 are double crimped in R1.CP/CS and 1 is only accessible in
the robot base.
• 1 protective ground
Number of signals, customer connections option Ethernet, Parallel&Air (803-2)
and DeviceNet, Parallel&Air (803-3):
• 8 (50V, 0.5A)
• 3 (300V, 2A)
• 2 DeviceNet
• 4 EtherNet
Number of signals, customer connections option Profibus, Parallel&Air (803-4):
• 8 (50V, 0.5A)
• 2 (300V, 2A)
• 2 Profibus
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.ETHER- 3HAC033181-001 • Hose coupling
on base NET • M12 connector, male
R2.CP/R2.CS R2.CP/R2.CS 3HAC025396-001 • Pins for cable area 0.21 - 0.93
mm 2
• Bottle shaped shrinking hose
• Angle shaped shrinking hose
• Hose coupling
Connector set R2.ETHER- 3HAC070439-001 • Pins for cable area 0.21 - 0.93
upper arm NET mm 2
• Bottle shaped shrinking hose
• Angle shaped shrinking hose

Continued
Power supply connections on the robot
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
Signal connection on the robot
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

Continued
not supplied)
CSY XP5.2.10 R2.CS.Y R1.CP/CS.b23
CSZ XP5.2.11 R2.CS.Z R1.CP/CS.b24

2.9 Test run after installation, maintenance, or repair
2.9 Test run after installation, maintenance, or repair
Safe handling
Use the following procedure after installation, maintenance, or repair, before
initiating motion.
DANGER
Initiating motion without fulfilling the following aspects, may increase the risk for
injury or cause damage to the robot.
Action
1 Remove all tools and foreign objects from the robot and its working area.
2 Verify that the robot is properly secured to its position by all screws, before it is powered
up.
3 Verify that any safety equipment installed to secure the position or restrict the robot
motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Verify that all safety equipment is installed, as designed for the application.
6 Verify that no personnel are inside the safeguarded space.
7 If maintenance or repair has been done, verify the function of the part that was main-
tained.
8 Verify the application in the operating mode manual reduced speed.
Collision risks
CAUTION
When programming the movements of the robot, always identify potential collision
risks before initiating motion.
Mechanical stops will not always stop the movements of the robot completely.

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.
The maintenance must be done by qualified personnel in accordance with the
safety requirements set forth in the applicable national and regional standards and
regulations.
Note
If the IRB 4600 is connected to power, always make sure that the IRB 4600 is
connected to protective earth and a residual current device (RCD) before starting
any maintenance work.
• Robot cabling and connection points on page 102.

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 (IRC5) or Operating manual - OmniCore.
The SIS used in OmniCore is further described in the Operating
manual - OmniCore.
Robots with the functionality Service Information System activated can show active
counters in the device browser in RobotStudio, or on the FlexPendant.
Overhaul
Depending on application and operational environment a complete overhaul may
be necessary in average around 40000 hours.
ABB 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 damage
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 115
Instructions for how to perform the different maintenance activities are found in
sections:
• Inspection activities on page 116
• Replacement activities on page 155
• Cleaning activities on page 197
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 197
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 .
Regularly ii
Inspection Information labels Every 12 months.
Inspection Dampers Every 12 months.
Inspection Pressure relief valve Every 12 months iii .
Inspection Mechanical stop Every 12 months.
Change Oil in axis-1 gearbox First change when DTC iv reads:
• 6,000 hours
Second change when DTC iv reads:
• 24,000 hours
Following changes:
• Every 24,000 hours.
Change Oil in axis-2 gearbox First change when DTC iv reads:
• 6,000 hours
• 24,000 hours
Following changes:

3 Maintenance
Continued
Maintenance activity Equipment Interval

Change First change when DTC iv reads:
• 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 iv 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 v
system of type RMU101 or
RMU102 (3-pole battery con-
tact)
Replacement Battery pack, measurement Battery low alert vi
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 115.
ii For protection type Clean Room variants, need to do regular check on the .
iii Check more often if the environment is very contaminated.
iv DTC = Duty Time Counter. Shows the operational time of the robot.
v 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.
vi 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 or Operating manual - OmniCore 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 117.
If the robot is suspended, follow the procedures in Inspecting the gearbox oil level
in a suspended robot (Other design than Type C and Type D) on page 120.
Note
If the suspended robot is design Type C and Type D, 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 level in a floor mounted robot on page 117.
The method described in this section of inspecting the oil level in a suspended
robot is only valid for Other design than Type C and Type D.
Read more about design Type C and Type D in section Type C of IRB 4600 on
page 414 and Type D of IRB 4600 on page 415.
Required equipment
Equipment Note
Only valid for Other design than Type C and 3HAC029646-001
Type D:
Oil plug sealing washer, gearbox
Lubrication oil See section Type of lubrication in gearboxes
on page 155.
on page 424.
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 and Type D
xx1200000632
A Oil plug, filling and inspection

B Oil plug, draining
Other design (1) than Type C and Type D
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, see Gearbox lubricants (oil or grease)
on page 36.
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.
4 Open the oil plug, inspection. See Location of oil plugs (floor mounted)
on page 117.

3 Maintenance
Continued
Action Note
5
Note A
Valid for Type C and Type D and Other
design (1) than Type C and Type D
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 and

Type D:
Measure the oil level at the oil plug hole.
Required oil level:
• 35 ± 3 mm below the surface for the
motor flange. xx1000000824
The oil level shall only just start to be ob-
served when looking through the oil filling Parts:
hole. See figure! • 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 157
8 Refit the oil plug, inspection. Tightening torque:
• 24 Nm
opened. Also repair possible damages of
the special Foundry Prime paint coat of the
robot. See Cut the paint or surface on the
robot before replacing parts on page 211.
Note
After all repair work, wipe the robot free

from particles with spirit on a lint free cloth.

3 Maintenance
Continued
Inspecting the gearbox oil level in a suspended robot (Other design than Type C and Type D)
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 and Type D.
Note
If the suspended robot is design Type C and Type D, 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 level in a floor mounted robot on page 117.
Note
If the suspended robot is Other design than Type C and Type D, 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

on page 36.
2
DANGER
Turn off all:

working area.
3
CAUTION

cess pressure.
4 Open the oil plug inspection on the axis 1 See the figure in:
gearbox. • Location of oil plugs (floor moun-
ted) on page 117

3 Maintenance
Continued
Action Note
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 157
7 Refit the oil plug. Tightening torque:
• 3-8 Nm
Note
Only valid for Other design than Type C

and Type D:
Before refitting the oil plug in the gearbox,
always replace the oil plug sealing washer
with a new one. If not there is a risk of
leakage.

Note


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
Type D:
on page 155.
Oil plug (Quick connect fitting) For article number see Spare part lists on
page 429.
on page 424.

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

on page 36.
2
DANGER
Turn off all:

working area.
3
CAUTION

cess pressure.
4
CAUTION
Always cut the paint with a knife and grind

the paint edge when disassembling parts.
See Cut the paint or surface on the robot
before replacing parts on page 211.
5 Open the oil plug, inspection (location de- See the figure in:
pends on how the robot is mounted). • Location of axis 2 gearbox on
page 123
Note
Always open the oil plug on top, depending

how the robot is mounted.
6 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.
7 Add oil if required. How to fill oil is described in section
on page 168

3 Maintenance
Continued
Action Note
• 24 Nm
Note

and Type D:
leakage.

Note


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 and Type D
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 and Type D
xx0800000306
A Oil plug, armhouse

B Oil plug, gearbox (not visible in this figure)
Required equipment
Equipment Note
on page 155.
on page 424.
Inspecting the oil level, axis 3 gearbox

Action Note
1
WARNING

on page 36.
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
CAUTION

6 Type C and Type D: Open the oil plug, arm- See the figure in:
house (pos. B). • Location of axis 3 gearbox on
Other design than Type C and Type D: Open page 126
the oil plug, armhouse.
Required oil level:
• oil in the gearbox shall be just below
the edge of the oil plug hole.
on page 172
• Other design than Type C and
Type D, in armhouse: 10 Nm
Other design than Type C and
Type D, in gearbox: 3 Nm
Type C and Type D, both plugs:
10 Nm
Note


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 155.
on page 424.
Inspecting the oil level, axis 4 gearbox

Action Note
1
WARNING

on page 36.
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 Maintenance
Continued
Action Note
3
DANGER
Turn off all:

ing area.
4
CAUTION

sure.
5
CAUTION

6 Open the oil plug. See the figure in:

• Location of axis 4 gearbox on
page 129
Required oil level:
• 35 ± 5 mm below the oil plug flange.
on page 179
9 Refit the oil plug, filling. Tightening torque:
• 10 Nm
Note


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 155.
on page 424.
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

on page 36.

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

ing area.
4
CAUTION

sure.
5
CAUTION

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

• Location of gearbox, axes 5-6 on
page 131

3 Maintenance
Continued
Action Note
• 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 131
8 Add oil if required. How to fill oil is decribed in section:

• Changing oil, axes-5 and -6 gear-
boxes on page 183
9 Refit the oil plugs. Tightening torque:
• 10 Nm
Note

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

on page 36.

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 131
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!

3 Maintenance
Continued
Action Note
4
DANGER
Turn off all:

ing area.
5
CAUTION

sure.
6
CAUTION

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

page 131
• 63 ±3 mm below the edge of the oil
plug hole.
boxes on page 183
10 Refit oil plug, wrist. Tightening torque:
• 10 Nm
Note

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.

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

ing area.
3
CAUTION

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

page 131
• 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 183
• 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

3 Maintenance
Continued
Cable harness, lower arm, Clean Room.
C
J
D K
L
E
G
M
N
H
xx2300001187
A Plug, upper
B Bracket, lower arm
C Cable harness
D Cable strap, lower arm (plastic)
E Sink cover
F Bracket, lower arm
G Cable straps, one not visible here (steel)
H Bracket, frame
J Bracket, armhouse
K Protection tube
L Middle bracket
M Plug, lower
N Protection tube
Required equipment
Equipment Note
on page 424.

3 Maintenance
Continued
Equipment Note
Circuit diagram See chapter Circuit diagram on page 431.
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 136
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 that the welding seam on the protec-
tion tubes is well sealed.
• If any part of the protection tubes
welding seam is cracking, replace the
complete cable harness. See Remov-
ing the complete cable harness on
page 214 and Refitting the complete
cable harness on page 229.
xx2300001355
6 Pull on each end of the protection tubes to

check that the protection tubes are tightly
attached to the brackets.
• If any end of the protection tubes has
any movement, replace the complete
cable harness. See Removing the
complete cable harness on page 214
and Refitting the complete cable har-
ness on page 229.

3 Maintenance
Continued
Action Note
7 Check that the two cable straps are still on
each end of protection tubes:
• If cable strap(A) is loosen or falling off
from one end, replace the cable strap.
See Replacing cable strap on the pro-
tection tubes on page 194.
• If cable strap(B) or two cable straps
on one end are loosen or falling off,
replace the complete cable harness. B
See Cut the paint or surface on the A
robot before replacing parts on
page 211.
xx2300001189
• A: The cable strap closed to the

bracket
• B: The cable strap installed in the
slot
8 Check that all brackets and straps are prop-
erly attached to the robot.
9 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.
Note


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 and Type D
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)

D Warning - "High temperature" (2 pcs)
H Label - Suspended robot

3 Maintenance
Continued
IRB 4600-60/2.05 and IRB 4600-40/2.55 Type C, Clean Room
K J
xx2300001224
A Warning - Symbol of flash

D Warning - High temperature
H AbsAcc Information Sign
J UL-Label
K Oil quality
L Label - Clean Room
Required equipment
Equipment Spare part number Note

Labels See Spare part lists on
page 429.

3 Maintenance
Continued
Inspecting labels
Use this procedure to inspect the labels on the robot.
Action Note
1
DANGER
Turn off all:

ing area.
2 Check all labels. See the figure in Location of information

labels on page 140.
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

Mechanical stop pin axis 1 See Spare part lists on
page 429.
Standard toolkit Content is defined in section
Standard tools on page 424.
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 144
3 How to replace the stop pin is described
Note in section Replacing stop pin axis 1 on
page 317.
If the mechanical stop pin has been deformed
or damaged, all of its mounting parts have to
be replaced.
xx0800000045
Parts:
A Attachment screws
B Bracket
C O-ring (2 pcs) - Not used if bracket (D)
is installed.
D Bracket
E Stop pin
4 Check that the mechanical stop pin is prop-

erly attached.

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

Note


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:

• -126° (Type C and Type D)
• -129° (other design than Type C and Type D)
B Movable mechanical stop. Limited to:
• +13.5° (Type C and Type D)
• +16.5° (other design than Type C and Type D)
C Movable mechanical stop. Limited to:
• -13.5° (Type C and Type D)
• -16.5° (other design than Type C and Type D)
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 number see Spare part lists on
page 429.
Standard toolkit Content is defined in section Standard tools on
page 424.

3 Maintenance
Continued
Equipment etc. Note

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.
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 147
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
5 seal and paint the joints that have been
Note


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 429.
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 149
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.
Note


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 424.
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.
5 Clean Room and Foundry Prime robots: seal

and paint the joints that have been opened.
Also repair possible damages of the special
Foundry Prime paint coat of the robot. See
Cut the paint or surface on the robot before
replacing parts on page 211.
Note


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 424.
CAUTION
Always cut the paint with a knife and grind the paint edge when disassembling
parts. See Cut the paint or surface on the robot before replacing parts on page 211.
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!

3 Maintenance
Continued
Action Note
1 Check that the signal lamp is lit when motors
are put in operation ("MOTORS ON").
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.
Note


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 available for registered users on myABB Business Portal,
www.abb.com/myABB.
Note
The type of oil pre-filled in axis-4 gear differs from the type of oil recommended
for field maintenance, due to differences in factory and customer sites
prerequisites. The two types of oil are fully equal and compatible.
Use the type of oil specified in Technical reference manual - Lubrication in
gearboxes, even though it differs from the oil specified in WebConfig.
Location of gearboxes
The figure shows the location of the gearboxes.
xx0800000311

3 Maintenance
Continued
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 and Type D: Used on the axes-1 and -
2 gearboxes.
Other design than Type C and Type D: Used
on the axis-2 gearbox.
Not valid for type C and Type D: Used when the robot is fitted in a suspended
Expansion container, gearbox axis 1 position.
(valid for other design than Type C and Type
D)

3 Maintenance
3.4.2 Changing the oil, axis-1 gearbox on floor mounted robots
General
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 and
Type D compared to Other design than Type C and Type D.
Both methods are described in this section.
Location of oil plugs

The oil plugs in axis 1 gearbox are located according to the following figures.
Type C and Type D
xx1200000632
A Oil plug, filling and inspection

(Also used for filling if an oil dispenser is used.)

3 Maintenance
Continued

Type A
xx0800000304
A Oil plug, filling

Type B
A
xx1000000669
A Oil plug, draining

B Oil plug, filling
3 Maintenance
Continued
Required equipment
Equipment Note
Type D:
Lubricating oil See section Type of lubrication in gearboxes
on page 155
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 155
on page 424.
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

on page 36.
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 and Type D: the base. page 155
• Other design than Type C and Type
D: the gearbox.
5 Only valid for Other design than Type C See the figure in:
and Type D: • Location of oil plugs on page 157
Replace oil plug draining quickly with a
nipple (M10x1.5) where a draining hose is Note
fitted.
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 155
7 Open the oil plug filling. See the figure in:
• Location of oil plugs on page 157
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 409 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:
Only valid for Other design than Type C Type D: 3-8 Nm
and Type D: Type C and Type D: 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, see Gearbox lubricants (oil or grease) on
page 36.
3
CAUTION
The gearbox can contain an excess of pressure

that can be hazardous. Open the oil plug 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 155
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 116
• 24 Nm
Note
Only valid for Other design than Type C and

Type D:
Before refitting the oil plug in the gearbox, al-
ways replace the oil plug sealing washer with
a new one. If not there is a risk of leakage.

3 Maintenance
3.4.3 Changing the oil, axis-1 gearbox on suspended robots
General
This section describes how to change the axis-1 gearbox oil in a suspended robot.
Note
The method of changing oil on the axis-1 gearbox is different on Type C and
Type D compared to Other design than Type C and Type D.
Note
Only valid for Type C and Type D!

If the robot has design Type C or Type D, the basic method for changing oil in a
suspended robot is to fill the same amount of oil that has been drained.
Measure the amount of oil drained and record the result. The same amount will
be added later.

The oil plugs in axis 1 gearbox are located according to the following figures
Type C and Type D

A
xx1000001436
A Oil plug for filling and venting

B Oil plug for draining
C Motor flange

3 Maintenance
Continued
xx1200000883
A Oil plug, venting

B Oil plug, draining and filling
Required equipment
Equipment Note
Type D:
Lubricating oil See section Type of lubrication in gearboxes
on page 155
in section:
page 155
Oil change equipment
Hose Used with the oil dispenser
on page 424.
CAUTION

Tip
In order to save time, a pneumatic oil dispenser can be used to suck the oil out
from the gearbox.

3 Maintenance
Continued
Action Note
1
DANGER
Turn off all:

working area.
2
WARNING

on page 36.
3
CAUTION

cess pressure.
4 Connect the oil dispenser to the oil plug for See Required equipment on page 163.
draining.
xx1800001271
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 162.
xx1800001272

3 Maintenance
Continued
Action Note
8 Using a low air pressure, start sucking the
oil out from the gearbox with the oil change
equipment.
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 and Type D!

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

page 36.

3 Maintenance
Continued
Action Note
3
CAUTION

4 Verify that the hose of the oil change equipment

is clean and then fit the quick connection to the
oil plug for filling.
xx1800001271
5 Open the oil plug for venting.
xx1800001272
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 155.
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 116
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:
Note Type D: 3-8 Nm
Type C and Type D: 24 Nm
Only valid for Other design than Type C and
Type D:
Before refitting the oil plug in the gearbox, al-
ways replace the oil plug sealing washer with
a new one. If not there is a risk of leakage.

3 Maintenance
Continued
Action Note
10 Seal and paint the joints that have been opened.
Foundry Prime paint coat of the robot. See Cut
the paint or surface on the robot before repla-
cing parts on page 211.
Note

Expansion container axis-1 gearbox, suspended mounted robots
Note
Not valid for Type C and Type D!

Expansion container is not needed on Type C and Type D.
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 95.

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
Type D:
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 155.
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 168.
on page 424.

3 Maintenance
Continued
CAUTION

Action Note
1
DANGER
Turn off all:

working area.
2
WARNING

on page 36.
3
CAUTION

cess pressure.
4 Either See the figure in:

• connect a nipple to the quick connect • Location of oil plugs on page 168
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

3 Maintenance
Continued
Action Note
7
WARNING

ation.
8
Note
There will be some oil left in the gearbox

after draining.
9 Refit oil plug. Tightening torque:

• 24 Nm
Note

and Type D:
leakage.

Action Note
1
DANGER
Turn off all:

working area.
2
WARNING

on page 36.
3
CAUTION

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


3 Maintenance
Continued
Action Note
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 155.
The amount of oil to be filled depends on

6 Inspect the oil level. How to inspect the oil level is described
in section:
• Inspecting the oil level, axis 2
gearbox on page 123
7 Refit oil plug. Tightening torque:
• 24 Nm
Note

and Type D:
leakage.

Note


3 Maintenance

The axis-3 gearbox is located in the upper arm rotational center.
Oil plugs are shown in the figure.
Type C and Type D
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 155.
in section:
page 155
Funnel
xx1200000862

on page 424.

3 Maintenance
Continued
CAUTION

There is an alternative method to drain the gearbox. See Draining - alternative
method on page 175.
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

page 36.
4
CAUTION


3 Maintenance
Continued
Action Note
5 Open the oil plug, armhouse See the figure in:
6 Type C and Type D: Open the other oil plug in See the figure in:
the armhouse and use it as a ventilation hole. • Location of oil plugs on page 172
Other design than Type C and Type D: 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 and Type
D, in armhouse: 10 Nm
D, in gearbox: 3 Nm
Type C and Type D, both plugs: 10
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 172
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 155
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 172
6 Connect the oil dispenser. One example can be found in section:
• Type of lubrication in gear-
boxes on page 155
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 172
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 155
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:
D, in gearbox: 3 Nm
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

page 36.
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 155.
Use a funnel.
Note
The amount of oil to be filled depends on the

amount previously being drained.
7 Inspect the oil level. How to inspect oil is described in

section:
• Inspecting the oil level, axis 3
gearbox on page 126

3 Maintenance
Continued
Action Note
D, in gearbox: 3 Nm
Nm
Note


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 155
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 424.
CAUTION
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

on page 36.
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

on page 36.
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 155.
Tip
Use a funnel.
Note

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

Note


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 155
on page 424.
CAUTION

3 Maintenance
Continued
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.
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

on page 36.
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 183
box and to fascilitate draining.
8 Drain the gearbox.
Note
9
WARNING

ation.

3 Maintenance
Continued
Draining axes-5 and -6 gearbox - wrist 12/20 kg

CAUTION
Action Note
1 Move the upper arm to a horizontal position.
2 Turn axis-4 to the calibration position. See the figure in Location of oil plugs on
page 183.
3
DANGER
Turn off all:

working area.
4
WARNING

on page 36.
5 Remove the oil plugs in the wrist. See the figure in Location of oil plugs on
page 183.
6 Turn axis-4 through 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 183
2 Move axis-5 to a position where the oil plug, See the figure in:
tilthouse points upwards. • Location of oil plugs on page 183

3 Maintenance
Continued
Action Note
3
DANGER
Turn off all:

working area.
4
WARNING

on page 36.
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 131
10 Refit both oil plugs. Tightening torque:
• 10 Nm
Note


3 Maintenance
Continued
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
DANGER
Turn off all:

working area.
4
WARNING

on page 36.
5 Open the oil plug, tilthouse. See in figure:


in section:
5 - 6 on page 131
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 or Operating manual - OmniCore for instructions.
WARNING
See Hazards related to batteries on page 38.

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 429.
Standard toolkit Content is defined in section Standard tools on page 424.
Circuit diagram See chapter Circuit diagram on page 431.
CAUTION

3 Maintenance
Continued
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.
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
The unit is sensitive to ESD on page 56
4
CAUTION
Always cut the paint with a knife and grind the paint
edge when disassembling parts. See Cut the paint
or surface on the robot before replacing parts on
page 211.
5 Remove the SMB battery cover. See the figure in Location of SMB
battery on page 190.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
6 Pull out the SMB battery. See the figure in Location of SMB
7 Disconnect the battery cable and remove the bat- See the figure in Location of SMB
tery. battery on page 190.
8 How to dispose of the used SMB battery, see
chapter Decommissioning on page 409.

3 Maintenance
Continued
Refitting SMB battery

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

2

3 Reconnect the battery cable to the SMB battery. See the figure in Location of SMB
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 190.
5 Secure the SMB cover with its attachment screws. See the figure in Location of SMB
Also repair possible damages of the special Foundry
Prime paint coat of the robot. See Cut the paint or
surface on the robot before replacing parts on
page 211.
Note

7 Update the revolution counter. Detailed in Updating revolution

counters on IRC5 robots on
page 382.
8
DANGER
Make sure all safety requirements are met when

performing the first test run. See Test run after in-
stallation, maintenance, or repair on page 110.

3 Maintenance
3.4.9 Replacing cable strap on the protection tubes
Location of cable straps

The cable straps are located at each end of the protection tubes, as shown in the
figure.
B
A
xx2300001189
• A: The cable strap closed to the bracket

• B: The cable strap installed in the slot
A The cable strap closed to the bracket
B The cable strap installed in the slot

3 Maintenance
Continued
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.
Equipment Note
Cable strap -
Standard toolkit Content is defined in section Standard tools on page 424.
Replacing the cable straps

Use this procedure to replace the cable strap.
Action Note
1 Move the robot to its calibration position. This is done in order to facilitate
the updating of the revolution
counter.
2
DANGER
Turn off all:

3

Cut and remove the loosen cable strap.

4 Clean the end of the protection tube and bracket
with isopropyl alcohol.

3 Maintenance
Continued
Action Note
5 Refit a new cable strap at the old position.
Tip
Make sure that the cable strap is installed in the

cable strap slot.
xx2300001225
Tip
The head of the cable strap should be aligned with

the screw on the bracket.
xx2300001226
6 Cut the redundant part of the cable strap.

7 Pull on the protection tube to check that it's tightly
locked to the bracket by the cable straps.

3 Maintenance
3.5.1 Cleaning the IRB 4600
3.5 Cleaning activities
DANGER
Turn off all:

to the robot, before entering the safeguarded 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 product 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 116.
2 Write down the oil level.
3 Inspect the oil level again after, for example, 6 months.
4 If the oil level is decreased then replace the gearbox.
Special cleaning considerations

This section specifies some special considerations when cleaning the robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning.
• Never point the water jet at connectors, joints, sealings, or gaskets.
• Do not use compressed air to clean the robot.
• Never use solvents that are not approved by ABB to clean the robot.
• Do not spray from a distance closer than 0.4 m.
• Do not remove any covers or other protective devices before cleaning the
robot.

3 Maintenance
Continued
Cleaning methods
The following table defines what cleaning methods are allowed 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 is highly re- No
cleaning deter- commended that
gent. the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
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.
Clean room Yes Yes. With light No No
cleaning deter-
gent, spirit or
isopropyl alco-
hol.
i Perform according to section Cleaning with water and steam on page 199.
Wiping with cloth

Additional cleaning instructions for Clean Room robots
ABB robots with protection types Clean Room are designed to be cleaned at a low
cleaning frequency, before entering the cleanroom environment, after robot
commissioning or during cleanroom maintenance.
Wipe-down cleaning method is recommended. Robot surfaces shall be wiped with
clean and low particle emission cleanroom cloth which is soaked in 70% ethanol
.
Use the following procedure to clean Clean Room robots:
1 Before cleaning, use the lint free cloth to remove dirt, debris or any other
contaminant from the to-be cleaned surfaces.
• Make sure no visible residues left.
• Never apply hard forces on or rub against the robot surfaces to remove
dirt or debris; otherwise, protective paint layers may be damaged.
2 Wet a clean cloth with the cleaning detergent and then wipe the robot painting
surfaces.
• Make sure no cleaning agents are sprayed onto robot surfaces or into
the robot structure.
• Wipe from the surface center to edge and always in the same direction.
3 Wait a few minutes for detergent volatilization.
• Make sure no residue of cleaning agents left on the robot surfaces
after wipe down cleaning.

3 Maintenance
Continued
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), provided that the robot is not
equipped with the option of motor cooling fans. 1 2
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
• Never point the nozzle at the following positions (example images):
Position Example of position
Rotational sealings
xx2300001604
Gaskets
xx2300001605
1 See Cleaning methods on page 198 for exceptions.

2 If the robot is equipped with a sleeve, do not open Axis 2 and 3 before rinsing, as this will damage the sealing ring.

3 Maintenance
Continued

Connectors
xx2300001606
Cable inlets
xx2300001607
Brake release buttons
xx2300001608

3 Maintenance
Continued

Press relief valve
xx2300001609
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. 3
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.
3 See Cleaning methods on page 198 for exceptions.

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

This chapter describes repair activities for the IRB 4600. Each procedure contains
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.
Report replaced units
Note
When replacing a part on the IRB 4600, report to your local ABB the serial number,
the article number, and the revision of both the replaced unit and the replacement
unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Safety information
Make sure to read through the chapter Safety on page 21 before commencing any
service work.
Note
If the IRB 4600 is connected to power, always make sure that the IRB 4600 is
connected to protective earth and a residual current device (RCD) 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.
The gearbox must be drained of oil before performing the 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, but do not refill the gearbox with oil before
performing the leak-down test.
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 3HAC042536-001 Shell Gadus S2
Used to grease the bearings, if not
specified otherwise.
Assembly of all bearings

Attend to 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
Note
This instruction is not valid for solid oil bearings.

4 Repair
Continued
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.
• 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 sealings
General
This section describes how to mount different types of sealings.
Equipment
Consumable Article number Note

Grease 3HAC042536-001 Shell Gadus S2
Rotating sealings
The following procedures describe how to fit rotating sealings.
CAUTION
Please observe the following before commencing any assembly of sealings:

• Protect the sealing during transport and mounting, especially the main lip
on radial sealings.
• Keep the sealing in its original wrappings or protect it well before actual
mounting.
• The fitting of sealings and gears must be carried out on clean workbenches.
• Use a protective sleeve for the main lip during mounting, when sliding over
threads, keyways or other sharp edges.
• Do not lubricate a static side of a sealing with grease, since this may result
in movement of the sealing during operation.
The only exception for lubrication of static sides of a sealing, is to use P-80
rubber lubrication gel against certain aluminium surfaces. If usage of P-80
is relevant, it is stated in the repair procedures.
Radial sealings
A radial sealing consists of a flexible rubber lip bonded to a rigid metal case. Only
one side of the sealing is static with a metal insert.
xx2300000433

4 Repair
Continued
Action Note
1 Check the sealing to ensure that:
• The sealing is of the correct type.
• There is no damage on the main lip.
2 Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.
3 Lubricate the sealing with grease just before fitting. Article number is specified in
(Not too early - there is a risk of dirt and foreign Equipment on page 207.
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
A B C
xx2000000071
A Main lip
B Grease
C Dust lip
Note
Ensure that no grease is ap-

plied to the red marked surface.

4 Repair
Continued
Action Note
4 Mount the sealing correctly with a mounting tool. A
Never hammer directly on the sealing as this may
result in leakage.
xx2000000072
A Gap
5 Make sure that no grease is left on the robot surface.
Flange sealings and static sealings

The following procedure describes how to fit flange sealings and static sealings.
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.
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.

4 Repair
Continued
Action Note
3 Check the o-ring grooves and mating surfaces.
They should be free of pores, contamination
and obvious scratches/damage.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Check that the o-ring is not squashed outside
the o-ring groove.
7 Make sure that no grease is left on the robot
surface.

4 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
For robots with protection type Clean Room
When replacing parts on the robot, it is important to make sure that after the
replacement, no particles will be emitted from the joint between the structure and
the new part, and that the easy cleaned surface is retained.
Required equipment
Equipment Spare parts Note

Sealing compound 3HAC026759-001 Sikaflex 521 FC. Color white.
Tooling pin Width 6-9 mm, made of wood.
Cleaning agent Ethanol
Knife
Lint free cloth
Touch up paint Clean Room/Hy- 3HAC036639-001 White
gienic
Touch up paint Standard/Foundry 3HAC067974-001 Graphite White
Plus
Touch up paint Standard/Foundry 3HAC037052-001 ABB Orange
Plus
Removing
Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
xx2300000950
2 Carefully grind the paint edge that is left on

the structure to a smooth surface.
Refitting
Action Description
1 Before the parts are refitted, clean the joint Use ethanol on a lint free cloth.
so that it is free from oil and grease.

4 Repair
Continued
Action Description
2 Place the tooling pin in hot water.
3 Seal all refitted joints with sealing compound.
xx0900000122
4 Use the tooling pin to even out the surface

of the sealing compound.
xx0900000125
5 For robots with protection type Clean Room For robots with protection type Clean
Wait 10 minutes. Room
Sikaflex 521FC skin dry time (10 minutes).
6 Use Touch up paint Clean Room/Hygienic, 3HAC036639-001
white to paint any damaged surfaces.
Note
Always read the instruction in the product

data sheet in the paint repair kit for Clean
Room/Hygienic.
Note
After all repair work, wipe the robot free from particles with spirit on a lint free
cloth.

4 Repair
4.2.5 The brake release buttons may be jammed after service work
4.2.5 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.

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 229.
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 218
• Removal in the frame Removing cable harness in frame on page 224
• Removal in lower arm and armhouse Removing cable harness in lower arm
and armhouse on page 225.
How to replace the SMB unit, brake release unit and motors can be found in:
• SMB unit Removing the SMB unit on page 249
• Brake release unit Removing the brake release board on page 256
• Motors Removing motors on page 320

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

4 Repair
Continued
C
J
D K
L
E
G
M
N
H
xx2300001187
A Plug, upper
C Cable harness
E Sink cover
H Bracket, frame
J Bracket, armhouse
K Protection tube
L Middle bracket
M Plug, lower
N Protection tube
Required equipment
Equipment Note
Deep well hexagon socket Width 30 mm
on page 424.

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 389.
no new reference values can be created,
then reference calibration is not possible.
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.ETHERNET (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.ETHERNET (if
used)
• E: R1.SMB
4
CAUTION

5 Remove the cover base.
C
xx0800000456
A Base
B Cover base
C Attachment screws
6 Disconnect connectors on the brake release
unit:
• X8
• X9
• X10

4 Repair
Continued
Action Note
7 Cut the cable straps securing the battery
cable.
xx0900000099
Parts:
• A: Cable straps (2 pcs)
8 Disconnect the battery cable.
9 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
10 Unscrew the nut for the air connection on
the inside of the bracket.

4 Repair
Continued
Action Note
11 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)
12 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
13 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
14 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 249

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

4 Repair
Continued
Action Note
18 Valid for Type C and Type D.
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
19 Valid for Other design than Type C and
Type D.
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
20 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 224

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 214.
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 320
3
CAUTION

4 Remove the bracket securing the cable See the figure in:
package to the frame. • Location of the cable harness on
page 215
5 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 215

4 Repair
Continued
Action Note
6 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)
7 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!
8 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 225
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 214 and frame Removing the
complete cable harness on page 214.

4 Repair
Continued
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 215 (Cable harness, lower arm)
3
CAUTION


4 Repair
Continued
Action Note
4 Remove the brackets on the lower arm.
D
C
xx0900000020
D
C
xx2300001190
Parts:
• A: Bracket, lower arm
• B: Bracket, lower arm
• C: Bracket, armhouse
• D: Cable bracket

4 Repair
Continued
Action Note
5 Remove the bracket on the armhouse.
xx0800000335
Parts:
• A: Tubular shaft unit
6 Remove the cable cover on the armhouse.
xx0800000338
Parts:
• A: Signal lamp
• B: Bracket
• C: Cable cover, armhouse
7 Remove signal lamp if used.
8 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 214.
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 233
• Refitting in the base Refitting the cable harness in the base on page 237
• Refitting in the lower arm and armhouse Refitting the cable harness in the
lower arm and armhouse on page 243.
How to refit the SMB unit, brake release unit and motors can be found in:
• SMB unit Refitting the SMB unit on page 252
• Brake release unit Refitting the brake release board on page 257
• Motors Refitting motors on page 329

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

4 Repair
Continued
C
J
D K
L
E
G
M
N
H
xx2300001187
A Plug, upper
C Cable harness
E Sink cover
H Bracket, frame
J Bracket, armhouse
K Protection tube
L Middle bracket
M Plug, lower
N Protection tube
Required equipment
Equipment Note
Deep well hexagon socket Width 30 mm
on page 424.

4 Repair
Continued
Equipment Note
Cable grease 3HAC042536-001 (Shell Gadus S2)
CAUTION
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 Clean the joints that have been opened. See

replacing parts on page 211
3 Apply cable grease on these surfaces: Cable grease is specified in:
• cable guide inside the hole • Required equipment on page 232
• the part of the cable harness that
runs through the cable guide.
4
Note
Two alternative methods to insert the cable

package in frame and base are presented
below. Chose one of the methods.

4 Repair
Continued
Action Note
5 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)
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!

4 Repair
Continued
Action Note
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.
8 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
9
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
10 Secure the cover to the frame with its attach-
ment screws.
xx0900000016
Parts:
• A: Frame
• B: Hole in frame
• C: Cover
11 Connect the axis-1 and axis-2 motor cables. How to refit the motor cables is described
in section:
• Refitting motors on page 329

4 Repair
Continued
Action Note
12 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.ETHERNET (if
used)
• J: R1.SMB
13 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 237
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 229
Action Note
1
DANGER
Turn off all:

to the robot, before entering the safe-
guarded space.

4 Repair
Continued
Action Note
2 Valid for Type C and Type D.
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 and
Type D.
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 and Type D. The principle of securing
the bracket on Type C and Type D 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 252

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.ETHERNET (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 230
21 Refit the cable straps securing the cable See the figure in:
harness to the frame. • Location of the cable harness on
page 230
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 243
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.

4 Repair
Continued
Action Note
2 Secure the brackets on the lower arm.
D
C
xx0900000020
D
C
xx2300001190
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 230 (Cable harness, lower arm)

4 Repair
Continued
Action Note
4 Push the cable harness carefully into the
armhouse.
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:
Note


4 Repair
Continued
Action Note
9 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 388.
General calibration information is included
in section Calibration on page 373.
10
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.
11
DANGER
Make sure all safety requirements are met

when performing the first test run. See Test
run after installation, maintenance, or repair
on page 110.

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.
Equipment Note
on page 424.

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
CAUTION

4 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)
5 Cut the cable straps securing the battery
cable.
6 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
7 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
8 Disconnect cable clamps.
A
xx0900000035
Parts:
A Cable clamps
9 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 248
move the SMB unit.
10 Remove the SMB unit.
11 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
12 Disconnect the remaining connectors on See the figure in:

the SMB unit: • Location of SMB unit on page 248
• 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.

3 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
4 Place the SMB unit on its attachment See the figure in:
screws. • Location of SMB unit on page 248
5 Secure the SMB unit with its attachment
screws.
6 Refit the cable clamps.
A
xx0900000035
Parts:
A Cable clamps

4 Repair
Continued
Action Note
7 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 248
Note

order not to damage cables or other com-
ponents!
8 Secure the battery cable with cable straps.

into position while at the same time check-
ing that no cables are damaged.
10 Secure the base cover with the attachment
screws.
C
xx0800000456
Parts:
A Attachment screws (6 pcs)
B Base cover
C Base
Note



4 Repair
Continued
Action Note
13
DANGER

on page 110.

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.
X8
X10
X9
xx1700000978

4 Repair
Continued
Required equipment
Equipment Note
Brake release board 3HAC065020-001 i DSQC1050
3HAC062021-001 ii DSQC1052
Other tools and procedures These procedures include refer-
may be required. See references to the tools required.
tions below.
i Valid for robots that are equipped with motors of Type A and Type B (see Product manual, spare
parts - IRB 4600).
Includes brake release board and harness.
ii Valid for robots that are equipped with motors of Type B (see Product manual, spare parts - IRB
4600).
Includes brake release board and harness.
Removing the brake release board

Use this procedure to remove the brake release board.
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 The unit is sensitive to ESD on page 56.
3
CAUTION

4 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
5 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)
6 Take a picture or make notes of how the
robot cabling is positioned in regard to the
brake release board.
7 Disconnect connectors X8, X9 and X10 from
the brake release board.
X8
X10
X9
xx1700000978
8 Remove the nuts securing the brake release

board.
9 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
The unit is sensitive to ESD on page 56.

4 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 255
5 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 X8
X10
are snapped down properly. X9
xx1700000978
6 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.

4 Repair
Continued
Action Note
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)
8 Secure the base cover with its attachment
screws.
9
WARNING
Before continuing any service work, follow

the safety procedure in section The brake
release buttons may be jammed after service
work on page 213!
10 Refit the push button guard to the SMB cover.

11 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.
Note

13
DANGER

on page 110.

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
• axis-1 gearbox
The location of the base and the complete arm system is shown in the figure.
xx0800000345
A Base
B Frame
C Lower arm
D Arm house (part of complete upper arm)
E Tubular shaft unit (part of complete upper arm)
F Wrist unit (part of complete upper arm)
Required equipment

Roundslings - Length: 2 m (2 pcs), 1.5 m (1 pcs)
Lifting capacity: 1,000 kg.
Support legs 3HAC15535-1 3 pcs
Guide pin, M8x150 3HAC15520-2 Always use guide pins in pairs.
4 Repair
Continued

Lifting eye - M8
3 pcs
Other tools and procedures may These procedures include refer-
be required. See references to ences to the tools required.
these procedures in the step-by-
step instructions below.
Cleaning agent - Loctite 7063
For cleaning.
Flange sealant - Loctite 574 (or equivalent)
For sealing.

Action Note
calibration:
Removing the base

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

4 Repair
Continued
Action Note
2 Jog the robot to:
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: -10°
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: 0°
3
DANGER
Turn off all:

to the robot, before entering the safe-
guarded space.
4
CAUTION

5 Drain the axis-1 gearbox. How to drain oil is detailed in section

Note on floor mounted robots on
page 157
Elapsed time varies depending on the tem-
perature of the oil.
6 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 218
Tip
on page 224
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 225

4 Repair
Continued
Action Note
7 Secure the robot with roundslings in an Dimensions are specified in Required
overhead crane. equipment on page 260.
Stretch the roundslings so that the robot C
weight is secured when removing founda- B
tion bolts in next step.
xx1100000582
A Roundsling 1.5 m
B Roundsling 2 m
C Roundsling 2 m
8
CAUTION

accordingly!
9 Remove the bolts that secure the robot to

the foundation.
10 Lift the robot and fit three support legs to
the robot base, using bolts, washers and
nuts.
DANGER
Working underneath the manipulator without

safely securing the support legs between
the robot base and the foundation will result
in serious or fatal injury.
Make sure the robot is stable and safely
secured to the foundation via the support
legs, before working underneath the robot.
Keep the lifting accessories stretched for xx1800000874
extra safety precautions.

4 Repair
Continued
Action Note
11 Lower the robot and secure the support legs
to the foundation, using bolts and washers.
xx1800000875
12 Remove the cover plate at the bottom of the

base.
xx1800000879

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

4 Repair
Continued
Action Note
14 Fit two guide pins in opposite holes in the Guide pin, M8x150: 3HAC15520-2
axis-1 gearbox. Always use guide pins in pairs.
xx1800000883
15
CAUTION
The arm system and axis-1 gearbox weighs

380 kg together.
All lifting accessories must be sized accord-
ingly.
16 Lift away the robot arm system.

Remove the guide pins, if the arm system
is about to be laid down on the floor. See
Illustration of robot put down on its side on
page 343.
xx1800000884
17
CAUTION
The weight of the base is 49 kg

accordingly.
18 Fit three lifting eyes to the base and secure Lifting eye: M8
with roundslings in an overhead crane or
similar.
xx1800000931

4 Repair
Continued
Action Note
19 Remove the support legs attachments
screws and remove the base from the sup-
port legs.
xx1800000885
Refitting the base

Use this procedure to refit the complete arm system to the base.
Action Note
1
CAUTION
The weight of the base is 49 kg

accordingly.
2 Fit three lifting eyes to the base and secure Lifting eye: M8
with roundslings in an overhead crane or
similar.
3 Fit the new base to the support legs and
secure with the attachment screws.
xx1800000885

5 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
6 Apply Loctite 574 around the screw holes
on the axis-1 gearbox as shown in the fig-
ure.
xx0800000353
Parts
A Loctite 574
B Screw hole in axis-1 gearbox
C Axis-1 gearbox
7
CAUTION
The arm system and axis-1 gearbox weighs

380 kg together.
All lifting accessories must be sized accord-
ingly.
8 Lift the arm system to the mounting site.

axis-1 gearbox. Always use guide pins in pairs.
xx1800000932

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

D are different from the ones on Other
design than Type C and Type D!
xx0800000357
Type C and Type D:

Tightening torque: 110 Nm.
xx1200000634
Parts:
• B: Base
• C: Other design than Type C and
Type D: Attachment screws M8x40
quality Steel 12.9 Gleitmo and
washers (24+24 pcs)
• C: Type C and Type D: Attachment
screws M12x50 quality Steel 12.9
Gleitmo and washers (24+24 pcs)
• D: O-ring (Not visible behind cover
plate in figure of Type C and Type
D)
• E: Cover plate
• F: Attachment screws M6x16 qual-
ity 8.8-A2F (5 pcs)
11 Apply some grease to the o-ring and refit
the o-ring between the cover and base.

4 Repair
Continued
Action Note
12 Refit the cover plate at the bottom of the Attachment screws: M6x16 quality 8.8-
base with its attachment screws. A2F (5 pcs)
xx1800000879
13 Remove the screws that secure the support

legs to the foundation.
DANGER
Stretch the roundslings to make sure that

the robot weight is secured.
xx1800000875
14 Lift the complete robot and remove the

support legs from the base.
xx1800000874
15 Lower the robot and secure it to the found- See Orienting and securing the robot on
ation. page 66.
Note


4 Repair
Continued
Action Note
18
DANGER

on page 110.

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

Type C and Type D
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

4 Repair
Continued

The complete upper arm is located as shown in the figure.
xx2300001230
A Upper arm
B Lower arm
C Washer (3 pcs)
xx1200000520
D Attachment screws M10x40 quality steel 12.9 Gleitmo (15 pcs)

E Plug, upper
F Attachment screws M6x16 8.8-A2F Torx pan head screw (4 pcs)
G Axis-3 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 and Type D: M10 (2 pcs)
Other design than Type C and Type D: M8 (2
pcs)
page 424.
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:
CAUTION
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 Repair
Continued
Action Note
4
CAUTION
The weight of the complete upper arm (in-

cluding the wrist) is 140 kg
accordingly.
5 Attach the lifting accessories to the upper See Attaching the lifting accessories to
arm. the upper arm on page 279.
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
CAUTION

9 Disconnect all motor cables from motors How to disconnect cables from motors is
axes 3, 4, 5 and 6. detailed in sections:

4 Repair
Continued
Action Note
10 Remove the bracket fitted on the tubular
shaft unit.
xx0800000335
Parts:
• B: Attachment screws M6x16 qual-
ity 8.8-A2F (2 pcs)
• C: Bracket
11 Remove the signal lamp, if used.
12 Remove the cable bracket on the armhouse.
xx0800000338
Parts:
• A: Signal lamp
• B: Bracket
13 Using caution, pull the cable package out
of the hole where the cable bracket was fit-
ted.

4 Repair
Continued
Action Note
14 For protection type Clean Room, remove
the attachment screws that secure the upper
plug to the lower arm.
Tip
The attachment screws are applied glue

when installed.
xx2300001227
15 Remove the attachment screws securing See the figure in:

the upper arm to the lower arm. • Location of the complete upper arm
on page 272
Note
Do not remove the attachment screws

securing the gearbox axis 3 to the arm-
house!
16 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 274.
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 274.
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 274.
both ends at the lifting hook. See figure Attaching the roundslings to the upper
arm on page 281.
4 Make a loop of the third round- Dimension is specified in Required equipment on
sling, running it around the wrist page 274.
unit. Run the roundsling on both See figure Attaching the roundslings to the upper
sides of the screws and fasten the arm on page 281.
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
3
CAUTION
The weight of the complete upper arm (in-

cluding the wrist) is 140 kg
accordingly.
4 Clean all assembly surfaces.

arm. the upper arm on page 279.
6 Fit guide pins to the upper arm. Specified in Required equipment on
page 274.
7 Lift the upper arm to the robot using an
overhead crane.
8 Release the brakes of the axis 3 motor.
9 Refit the upper arm to the lower arm with See the figure in:
its attachment screws. • Location of the complete upper arm
on page 272
Note Tightening torque Other design than
Type C and Type D:
Use new attachment screws! • 35 Nm
It may be necessary to turn the gear by ro- Tightening torque and angle Type C and
tating the motor pinion with a rotation tool, Type D:
motor beneath the motor cover. • 50 Nm and 90° angle
10 For protection type Clean Room, apply the

glue (Loctite 243) to the attachment screws
of the upper plug.
Tip
If use an old attachment screw, remove the

glue to clean the screw first.
11 For protection type Clean Room, refit the

attachment screws to secure the upper plug
to the lower arm.
xx2300001227

4 Repair
Continued
Action Note
12 Using caution, push the cable package
through the hole where the cable bracket
will be fitted.
xx0800000338
Parts:
• A: Signal lamp
• B: Bracket
13 Refit the cable bracket with its attachment
screws.
14 Reconnect all motor cables. How to connect motor cables is detailed
in sections:
15 Refit the bracket on the tubular shaft unit.
xx0800000335
Parts:
ity 8.8-A2F (2 pcs)
• C: Bracket
16 Refit the signal lamp, if used.

4 Repair
Continued
Action Note
Note


19
DANGER

on page 110.

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 424.
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 179
figure.
xx0800000336

4 Repair
Continued
Action Note
4
DANGER
Turn off all:

working area.
5
CAUTION

6 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
7 Place the cable package in a way that it will
not be damaged in the continued removal
procedure.
8 Remove motors axes 4, 5 and 6. How to remove motors is described in
section:
9 How to remove the wrist unit is detailed
Tip in section:
• Removal of wrist unit on page 294
If only the tubular shaft unit shall be re-
placed, it is a good idea to remove the wrist
unit at this stage.
10
CAUTION
The robot arm tube weighs 65 kg.

accordingly.

4 Repair
Continued
Action Note
11 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.
12 Remove the attachment screws that secure See the figure in:
the tubular shaft unit. • Location of tubular shaft unit on
page 285
13 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 285.
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.

3 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
4 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)
5
CAUTION
The robot arm tube weighs 65 kg.

accordingly!
6 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.
7 Fit guide pins in the upper arm house. Specified in Required equipment on
page 285.
8 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
9 Secure the tubular shaft unit with its attach- See the figure in:
ment screws. • Location of tubular shaft unit on
page 285
Note Tightening torque: 22 Nm
For Protection type, Clean Room variants,

apply some sikaflex 521 on the screws to
protect any unpredictable pollution.
10 Refit motors axes 4, 5 and 6. How to refit motors is described in sec-

tion:
11 Perform a leak-down test. See Performing a leak-down test on
page 204.
12 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
13 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 295
14 Refill gearbox axis 4 with oil. How to refill oil in gearbox is described in
section:
on page 179

4 Repair
Continued
Action Note
Note

17
DANGER

on page 110.

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
There are two versions of the wrist, one with an o-ring and one with a sealing. Make
sure to order the correct spare parts.
IRB 4600 -20/2.50
A
B
C
D
G
E
xx0800000341
xx1800003343
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)
Sealing (lower image)
G Guide pin
(only available for robots that are calibrated with Axis Calibration)

4 Repair
Continued
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
Sealing parts - IRB 2600.
Measuring tool For adjusting the play.
on page 424.

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.

4 Repair
Continued
Action Note
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 183
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
CAUTION
Always cut the paint with a knife and grind the

paint edge when disassembling parts. See Cut
7 Remove the attachment screws and carefully See the figure in:
remove the wrist unit. • Location of wrist unit on
page 292
CAUTION
Do not damage the gears.
Refitting of wrist unit

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

area.

4 Repair
Continued
Action Note
Cut the paint or surface on the robot before re-
placing parts on page 211
3 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
4 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
6 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 292
7 Check the o-ring or sealing. Replace if dam- See the figure in:
aged. • Location of wrist unit on
page 292
8 Prepare the refitting of the wrist by inserting the
attachment screws and washers in the upper
arm tube.
9
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.
10 Carefully put the wrist unit in its place on the

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

wrist unit.
11 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 329.
xx1000000223
Parts:
• A: Gears on drive shaft unit,
axes 5-6
• B: Gears on the wrist
12 Secure the wrist unit with its attachment screws See the figure in
and washers. • Location of wrist unit on
page 292

4 Repair
Continued
Action Note
13 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 300
• Measuring the play, axis 6 on
page 303
page 204.
15 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 183
Note

17 Re-calibrate 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 388.
General calibration information is in-
cluded in section Calibration on
page 373.
18
DANGER
Make sure all safety requirements are met when

performing the first test run. See Test run after
installation, maintenance, or repair on page 110.

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

Standard toolkit - Content is defined in sec-
tion Standard tools on
page 424.
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 Article number is specified in Required
disc. equipment on page 300.

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: 207.5 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: 207.5 mm
• C: 135 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: 0.10 mm
• IRB 4600 -20/2.50: 0.08 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 424.
(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 Article number is specified in Required
disc. equipment on page 303.

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: 207.5 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
• 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: 100 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: 0.19
mm

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

Type C and Type D
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)

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)

xx2300001193
A Upper arm
B Axis-3 gearbox

4 Repair
Continued
C Washer with five holes (3 pcs)
xx1200000520

E Plug, upper
F Attachment screws M6x16 8.8-A2F Torx pan head screw (4 pcs)
G Lower arm
H Washers 3HAC077381-001 (2 pcs)
J Attachment screws M6x16 8.8-A2F Torx pan head screw (2 pcs)
K Middle bracket
L Attachment screws M6x16 8.8-A2F Torx pan head screw (4 pcs)
M Plug, lower
N Attachment screws M12x50 quality Steel 12.9 Gleitmo (18 pcs)
P Washer (18 pcs)
Q Axis-2 gearbox
R Frame
Required equipment
Equipment Note
Lower arm For spare parts no. see Spare parts - Lower
arm and motors in Product manual, spare
parts - IRB 2600.
Lifting eye Type C and Type D
M10
M8
on page 424.

4 Repair
Continued

Action Note
calibration:
Removing the lower arm

Use this procedure to remove the lower arm.
Action Note
figure.
xx0800000336

4 Repair
Continued
Action Note
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 224
• Removing cable harness in lower
arm and armhouse on page 225
5 Secure the upper arm with a roundsling in
an overhead crane.
6
CAUTION


the attachment screws that secure the plugs
to the lower arm.
Tip

when installed.
xx2300001191

4 Repair
Continued
Action Note
the attachment screws that secure the
middle bracket to the lower arm.
xx2300001192
9 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 276
10
CAUTION
The robot lower arm weighs 65 kg.

accordingly!
11 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 and Type D, but the principle of fitting
the lifting lug is the same on Type C and
Type D.
xx0800000379
Parts:
• A: Lifting lug

4 Repair
Continued
Action Note
12 Remove the attachment screws and wash-
ers that secure the lower arm to the axis-2
gearbox.
xx1800000935
13 Remove the lower arm.
Refitting the lower arm

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

working area.

3
CAUTION
The robot lower arm weighs 65 kg.

accordingly!

4 Repair
Continued
Action Note
4 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 and Type D, but the principle of fitting
the lifting lug is the same on Type C and
Type D.
xx0800000379
Parts:
• A: Lifting lug
5 Secure the lower arm with a roundsling in
an overhead crane and lift it to the robot.
6 Refit the attachment screws and washers Attachment screws: M12x50 quality steel
to secure the lower arm to the axis-2 gear- Gleitmo 12.9 (18 pcs)
box. Tightening torque: 110 Nm.
xx1800000935
7 Secure the complete upper arm with round-

slings in an overhead crane and lift it to the
robot.
8 Refit the complete upper arm. How to refit the complete upper arm is
• Refitting the complete upper arm
on page 281

4 Repair
Continued
Action Note
9 For protection type Clean Room, refit the Attachment screws: M6x16 8.8-A2F Torx
attachment screws to secure the middle pan head screw(2 pcs)
bracket to the lower arm. Washers: 3HAC077381-001 (2 pcs)
xx2300001192

of the plugs.
Tip

11 For protection type Clean Room, refit the Attachment screws: M6x16 8.8-A2F Torx
attachment screws to secure the plugs to pan head screw(8 pcs)
the lower arm. Tightening torque: 0.3 Nm.
xx2300001191
12 Refit the cable package. How to refit the cable package in frame,
lower arm and armhouse is described in
sections:
frame on page 233
page 243

4 Repair
Continued
Action Note
Note


Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 388.
15
DANGER

on page 110.

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) - Not used if bracket (D) is installed.
D Bracket
E Stop pin
Required equipment
Equipment Note
Stop pin For spare parts number, see Spare parts -
Frame and base in Product manual, spare
parts - IRB 2600.
page 424.

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
CAUTION

3 Remove the attachment screws securing See the figure in

the bracket and stop pin. • Location of stop pin axis 1 on
page 317
4 Remove the bracket and stop pin. See the figure in
• Location of stop pin axis 1 on
page 317
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.


4 Repair
Continued
Action Note
3 Fit the two o-rings on the stop pin. See the figure in
Note page 317
The o-rings are not used when bracket (D)

is installed.
4 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
5 Secure the stop pin together with bracket - (Loctite 2400 (or equivalent Loctite 243)).
(D) on the frame with its attachment screws. Tightening torque: 10 Nm
Use Locking liquid
See the figure in
page 317
Note

7
DANGER

on page 110.

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 333
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 333
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 424.
CAUTION
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

4 Repair
Continued
Motor Weight in kg
Axis-5 motor 8 kg
Axis-6 motor 8 kg
CAUTION
All lifting equipment must be sized accordingly!

Action Note
calibration:

4 Repair
Continued
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
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 168

4 Repair
Continued
Action Note
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 172
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!
Action Note
take actions accordingly prior to beginning the
repair procedure.
2 Move the robot to the recommended position Also see
for the motor that shall be removed. • Position of robot on page 324
3
DANGER
Turn off all:

area.
4 Check if the gearbox needs to be drained. Also see

• Draining gearbox on page 324
5
CAUTION
Always cut the paint with a knife and grind the

paint edge when disassembling parts. See Cut

4 Repair
Continued
Action Note
6 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.
7 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 87
8 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 320
Remove the cable gland cover. • Location of axis-1 and axis-2
motors on page 320
Remove the connection box. • Location of axis-1 and axis-2
motors on page 320
Note
Only needed if the motor shall be replaced with

a new one.
11 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.

4 Repair
Continued
Action Note
12 Only applicable to axis-3 motor!
Remove the bracket from the axis-3 motor.
xx0800000390
Parts:
• A: Axis-3 motor
• B: Bracket
13 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 connector. • Axis-2 motor: R2.MP2
• Axis-3 motor: R2.MP3
Tip • Axis-4 motor: R2.MP4
• Axis-5 motor: R2.MP5
For axis-2 and axis-3 motors: release the mo- • Axis-6 motor: R2.MP6
tor brake until the arm firmly rests on the
damper for each axis respectively. See posi- Connect to pins:
tions in Position of robot on page 324. • + : 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.
14
Note
Whenever parting/mating motor and gearbox,

the gears may be damaged if excessive force
is used!
15 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 320
(Motor axis 1).
16 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.

4 Repair
Continued
Action Note
17 Remove the motor!
CAUTION
Lift the motor gently in order not to

damage pinion or gears.
18 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 320
tion.
19 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 320
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 on myABB
business portal (www.abb.com/myABB).
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 333
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 333
B Attachment screws, axis-4, axis-5 and axis-6 motors, (3x4 pcs) + washers. See
Tightening torques and attachment screws on page 333
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 424.
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 429.
CAUTION
Weights
The motors for the different axes weighs according to the table:
Motor Weight in kg
Axis-1 motor 13 kg

4 Repair
Continued
Motor Weight in 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
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.

4 Repair
Continued
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.
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 168
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 172
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 333
Motor, axis 3 Screwlengths depending 8.8-A2F 22 Nm
on flange thickness on
page 333
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

4 Repair
Continued
xx0900000443
A Flange thickness
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 Apply Loctite 574 on the o-ring.
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 87.
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 Also see
Note • Preparations before the refitting
of motors on page 334
Before starting the refitting of the motor, first
make the necessary preparations!
2
Note
Whenever parting/mating motor and gearbox,

the gears may be damaged if excessive force
is used!

4 Repair
Continued
Action Information
4 Place the motor carefully in the gearbox.
5 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!
6 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
7 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
8 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.
9 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 339.

4 Repair
Continued
Action Information
10 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 333
Apply the correct tightening torque!
11 Disconnect the brake release voltage.

12 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 329
Note
Make sure that the o-ring is in place!
13 Applicable to motor axis 3!

Refit the bracket on motor axis 3.
xx0800000390
Parts:
• A: Motor axis 3
• B: Bracket
14 Reconnect the motor cables.
15 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 329
Make sure that the o-ring is in place!
Note
Make sure that the cover is tightly

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

Refill gearbox oil. scribed in sections:
on page 168
on page 172
17 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
18 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
See Cut the paint or surface on the robot before
replacing parts on page 211.
Note

20 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 388.
General calibration information is in-
cluded in section Calibration on
page 373.
21
DANGER

when performing the first test run. See Test run
after installation, maintenance, or repair on
page 110.

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 424.
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. The exploded view only shows the
principle of the assembly. The actual replacing is recommended to be done with
the robot resting on its side.
Type C and Type D
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 429.
Guide pins Type C and Type D: Guide pin, M10x150:
3HAC15521-2/ Other design than Type C and Type
D: Guide pin, M8x150: 3HAC15520-2
Used to guide the gearbox during removal/refitting.
Always use guide pins in pairs.
Sikaflex 521 FC, color white 3HAC026759-003
Guide for reduction gear 3HACxxx
Used to guide axis-1 gear and frame during refit-
ting.

4 Repair
Continued
Equipment Note
page 424.
ures in the step-by-step instructions
below.

Action Note
calibration:

4 Repair
Continued
Illustration of robot put down on its side

The robot is put down on its side for a safe removal of the axis-1 gearbox. Prepare
an area on the floor with cardboard, plastic foam or similar and prepare higher
support for the wrist.
Make sure the cabling brackets on the lower arm are unfastened and moved out
of the way so that the cabling is not getting squeezed.
xx1800000593
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 157
3 Jog the robot to:
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: -10°
• Axis 4: 0°
• Axis 5: 0°
• Axis 6: 0°
4
DANGER
Turn off all:

to the robot, before entering the safeguarded
space.

4 Repair
Continued
Action Note
5
CAUTION

6 Remove the axis-1 motor. See Removing motors on page 320.

7 Remove the complete arm system from the See Removing the base on page 261.
base and lay down the robot on its side.
xx1800000593
8 Fit a lifting lug in the uppermost hole for the

base attachment screws.
xx0800000440
A Roundsling
B Lifting lug
C Uppermost base attachment hole
D Axis-1 gearbox
9
CAUTION
The gearbox weighs 27 kg.

accordingly!
10 Secure the gearbox in an overhead crane or

similar.
11 Remove the attachment screws securing the See the figure in:
gearbox. • Location of gearbox on page 340

4 Repair
Continued
Action Note
12 For protection type Clean Room, dig out the
glue from the countersink as clean as pos-
sible until the countersink can be used for B
loosing the screws with a wrench.
A
xx2300001363
A Screws (16 pcs)

B Pin holes (2 pcs)
13 Remove two gearbox attachment screws
opposite to each other and fit two guide pins
into the holes.
xx1800000789
Type C and Type D: Guide pin, M10x150:

3HAC15521-2/ Other design than Type
C and Type D: Guide pin, M8x150:
3HAC15520-2
Always use guide pins in pairs!
14 Remove the remaining attachment screws
and washers.
xx1800000790
15
Note
Whenever parting/mating motor and gear-

box, the gears may be damaged if excessive
force is used!

4 Repair
Continued
Action Note
16
Note
There will be some excess oil running out

of the gearbox when it is removed. Use
some absorbent material to catch the oil.
17 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.
xx1800000791
Refitting gearbox axis 1

Use these procedures to refit the gearbox.
Refitting the gearbox to the frame
Action Note
1
DANGER
Turn off all:

working area.


4 Repair
Continued
Action Note
3 Check the radial sealing in the frame.
Replace if damaged.
xx1800000794
4 Fit a lifting lug in the uppermost hole for the

base attachment screws.
xx0800000440
A Roundsling
B Lifting lug
C Uppermost base attachment hole
D Axis-1 gearbox
5 Only valid for Other design than Type C
and Type D:
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 A
the figure. The oil plugs shall be placed in
the openings in the frame.
B
xx0800000441
A Opening for oil plug in frame

B Oil plug

4 Repair
Continued
Action Note
6 Apply grease on the o-ring. See the figure in:
• Location of gearbox on page 340
Replace o-ring if damaged.
8 Fit two guide pins to the frame.
xx1800000793
Type C and Type D: Guide pin, M10x150:

3HAC15521-2/ Other design than Type
C and Type D: Guide pin, M8x150:
3HAC15520-2
Always use guide pins in pairs!
9 Fit the guide for the gear on top of the pro- Guide for reduction gear: 3HACxxx.
tection tube.
It protects the radial sealing from being
damaged during refitting.
xx1800000795
10
CAUTION

accordingly!

4 Repair
Continued
Action Note
11 Lift the gearbox onto the guide pins and
slide it into position, using caution.
Check that the radial sealing in the frame
tube does not get damaged.
and Type D:
Double check that the oil plugs are in the
correct position.
xx1800000791
xx0800000441
A Opening for oil plug in frame

B Oil plug
12 Secure the gearbox with its attachment
screws and washers.
Note
For Protection type, Clean Room variants,

apply some sikaflex 521 on the screws to
protect any unpredictable pollution.
13 Remove the guide pins from the frame and

secure the remaining two screws.
xx1800000790

Type D: 35 Nm
• Type C and Type D: 68 Nm

4 Repair
Continued
Action Note
14 For protection type Clean Room, apply
Sikaflex 521 to the countersink of the
screws and the pin holes on the axis-1 B
gearbox.
A
15 For protection type Clean Room, use a plate
to clean the overflowing glue to make the
outer surface as flat as possible.
xx2300001364
A Screws (16 pcs)

B Pin holes (2 pcs)
16 Remove the guide from the protection tube.
xx1800000796
Refitting the arm system to the base
Action Note
1 Refit the complete arm system to the base. See Refitting the base on page 267.
2 Refit the axis-1 motor. See Refitting motors on page 329.
3 Refit the cable harness in the base, the Also see
frame and the lower arm. • Refitting the cable harness in the
base on page 237
frame on page 233
page 243
.
4 Refill oil in the gearbox. See Changing the oil, axis-1 gearbox on
floor mounted robots on page 157.

4 Repair
Continued
Action Note
Note


7
DANGER

on page 110.

4 Repair
Location of gearbox axis 2

The gearbox is located as shown in the figure.
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

Gearbox See Spare part
lists on page 429.
Rotation tool 3HAB7887-1

4 Repair
Continued

Lifting accessories - Roundslings.
Guide pin, M12x150 3HAC13056-2 Always use guide pins in pairs.
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!

4 Repair
Continued
Action Note
1 Decide which calibration routine to
use, and take actions accordingly prior
to beginning the repair procedure.
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 168
5
CAUTION
Always cut the paint with a knife and

grind the paint edge when disas-
sembling parts. See Cut the paint or
surface on the robot before replacing
parts on page 211.

4 Repair
Continued
Action Note
6 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
xx2300001229
7
CAUTION
The weight of the complete upper and

lower arm together is 205 kg
All lifting accessories used must be
sized accordingly.
8 Attach a roundsling around the upper

arm house.
9 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.

4 Repair
Continued
Action Note
10
DANGER
Turn off all:

working area.
11 For protection type Clean Room, re-

move the attachment screws that se-
cure the lower plug to the lower arm.
Tip
The attachment screws are applied

glue when installed.
xx2300001228
12 Remove the attachment screws and

washers that secure the lower arm to
the axis-2 gearbox.
xx1800000935
13 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.
14
CAUTION
The gearbox weighs 51 kg

All lifting accessories used must be
sized accordingly!

4 Repair
Continued
Action Note
15 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 that se-
cure the lower arm to the axis-2 gearbox
16 Secure the gearbox with a roundsling
in an overhead crane or similar.
17 Remove the attachment screws and See the figure in:
washers that secure the gearbox to the • Location of gearbox axis 2 on page 352
frame.
18 Fit guide pins to help guiding the Guide pin, M12x150: 3HAC13056-2
gearbox out from the frame. Always use guide pins in pairs.
19 If necessary, use removal tools to re-
move the gearbox. Note
Always use removal tools in pairs diagonal to

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

gearbox or pinion!

4 Repair
Continued
Refitting gearbox axis 2

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

working area.
2
CAUTION

3
CAUTION
The gearbox weighs 51 kg

accordingly!
4 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.

4 Repair
Continued
Action Note
6 Apply some grease on the o-ring before fit- O-ring: 3HAB3772-120.
ting. See the figure in:
Valid for Type C and Type D: • Location of gearbox axis 2 on
Replace if damaged. page 352
frame. Always use guide pins in pairs.
8 Secure the gearbox with a roundsling in an
overhead crane or similar.
10 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 352.
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
11 Secure the gearbox with its attachment See screw dimension in the figure in:
screws and washers. • Location of gearbox axis 2 on
page 352
Tightening torque: 110 Nm
page 204.
13 Fit the guide pins to the gearbox.
14
CAUTION
The weight of the complete upper and lower

arm together is 205 kg
accordingly.
15 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.

4 Repair
Continued
Action Note
16 Refit the attachment screws and washers Attachment screws: M12x50 quality steel
to secure the lower arm to the axis-2 gear- Gleitmo 12.9 (18 pcs)
box. Tightening torque: 110 Nm.
xx1800000935
17 For protection type Clean Room, r apply the

of the lower plug.
Tip


attachment screws to secure the plug to the
lower arm.
xx2300001228

4 Repair
Continued
Action Note
19 Refit the cable brackets and cable strap to
the lower arm.
B
C
xx1100000946
A Cable bracket
B Cable bracket
C Cable strap
xx2300001229
20 Refill the gearbox with lubrication oil. How to fill the gearbox with oil is de-
scribed in section:
on page 168
Note


4 Repair
Continued
Action Note
23
DANGER

on page 110.

4 Repair
Location of gearbox axis 3

The gearbox is located as shown in the figure.
Type C and Type D
xx1200000638
A Upper arm
B Axis-3 gearbox
C Washers (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
Equipment Art. no. Note

Gearbox See Spare part lists on page 429.
Guide pins Type C and Type D: M10 (2 pcs)
Other design than Type C and
Type D: M8 (2 pcs)
Used to guide the gearbox and the
upper arm during removal/refitting.
Rotation tool 3HAB7887-1

4 Repair
Continued
Equipment Art. no. Note

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 172

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

working area.
5
CAUTION

6 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

4 Repair
Continued
Action Note
7 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 279
9 Connect the 24 VDC power supply to the
axis-3 motor and release the brakes.
10 Releasing the brakes of the axis-3 motor
unloads the weight of the upper arm by
stretching the roundslings.
the attachment screws that secure the upper
plug to the lower arm.
Tip

when installed.
xx2300001227
12 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 272
Note
Do not remove the attachment screws se-

curing the gearbox axis 3 to the armhouse!
13
CAUTION
The robot upper arm weighs 140 kg.

accordingly!
14 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.

4 Repair
Continued
Action Note
15
CAUTION

accordingly!
16 Remove two attachment screws diagonally Always use guide pins in pairs!
located and insert guide pins.
17 Remove the remaining attachment screws See the figure in:
that secures the gearbox. • Location of gearbox axis 3 on
page 363
18
Note
There will be some surplus oil in the gear-

box. Place some absorbant cloth or similar
under the gearbox.
19 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.
Refitting the gearbox axis 3

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

working area.
2
CAUTION


4 Repair
Continued
Action Note
3
CAUTION

accordingly!

Remove any painting or other contamination
from the assembly surfaces, with a knife.
5 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 363
6 Fit two guide pins in two opposite screw Always use guide pins in pairs!
holes in the upper arm.
7 Remove the arm house cover.
8 Attach the rotation tool on the axis-3 motor.
10 Lift the gearbox onto the guide pins.
11
Note
Whenever parting/mating motor and gear-

box, the gears may be damaged if excessive
force is used!
12 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 364.
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.
13 Rotate the motor pinion and slide the gear-

box into position.
14 Secure the gearbox with its attachment See the figure in:
screws and washers. • Location of gearbox axis 3 on
page 363
15 Remove the guide pins and replace them
with the remaining attachment screws.
page 204.
17 Fit guide pins in the upper arm. Specified in Required equipment on
page 364.

4 Repair
Continued
Action Note
18 Move the upper arm to its mounting posi-
tion.
(With the brakes of the axis 3 motor still re-
leased.)
19 Refit the upper arm to the lower arm with See the figure in:
its attachment screws. • Location of the complete upper arm
on page 272
Tightening torque:
• Type C and Type D: 50 Nm and
90° angle
Type D: 35 Nm
20 Remove the guide pins and replace with the
remaining attachment screws.
21 Remove the 24 VDC power supply.
of the upper plug.
Tip


attachment screws to secure the upper plug
to the lower arm.
xx2300001227

4 Repair
Continued
Action Note
24 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)
25 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
26 Refill the gearbox with lubrication oil. How to fill the gearbox with oil is de-
scribed in section:
on page 172
27 CSeal and paint the joints that have been
Note


4 Repair
Continued
Action Note
29
DANGER

on page 110.

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 388.
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.
Requires that the robot is dressed with the same
tools and process equipment during calibration as
during creation of the reference values.
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 serial measurement board (SMB) or
other robot memory.
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 (IRC5).
A robot calibrated with Absolute accuracy has
the option information printed on its name
plate (OmniCore).
To regain 100% Absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy after repair or maintenance that
affects the mechanical structure.
xx0400001197

5 Calibration
Continued
Type of calibration Description Calibration method

Optimization Optimization of TCP reorientation perform- Wrist Optimization
ance. The purpose is to improve reorientation
accuracy for continuous processes like weld-
ing and gluing.
Wrist optimization will update standard calib-
ration data for axes 4, 5 and 6.
Note
For advanced users, it is also possible to use

the do the wrist optimization using the RAPID
instruction WristOpt, see Technical reference
manual - RAPID Instructions, Functions and
Data types.
This instruction is only available for OmniCore
robots.
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, contact the local ABB Service.
Brief description of calibration methods

Calibration Pendulum method
Calibration Pendulum is a standard calibration method for calibration of many of
ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S). This
calibration method is not used on OmniCore robots.
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. 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.

5 Calibration
Continued
Wrist Optimization method

Wrist Optimization is a method for improving reorientation accuracy for continuous
processes like welding and gluing and is a complement to the standard calibration
method.
The actual instructions of how to perform the wrist optimization procedure is given
on the FlexPendant.
CalibWare - Absolute Accuracy calibration

The CalibWare tool guides through the calibration process and calculates new
compensation parameters. This is further detailed in the Application
manual - CalibWare Field.
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 replacements that do not include taking apart the robot
structure, standard calibration is sufficient.
The Absolute Accuracy option varies according to the robot mounting position.
This is printed on the robot name plate for each robot. The robot must be in the
correct mounting position when it is recalibrated for absolute accuracy.
References
Article numbers for the calibration tools are listed in the section Special tools on
page 425.
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 re-calibrated 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 382. 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 reachability of a robot
is changed, it needs to be re-calibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new
absolute accuracy.
Robot is not floor mounted

The original calibration data delivered with the robot is generated when the robot
is floor mounted. If the robot is not floor mounted, then the robot accuracy could
be affected. The robot needs to be calibrated after it is mounted.

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

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
xx1700001814
D Synchronization mark, axis 4

E Synchronization mark, axis 5
F Synchronization mark, axis 6
The two tips of the arrows should be inside the corresponding groove on the tilt
housing when in synchronization position.

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
5.3.1 Updating revolution counters on IRC5 robots
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 1510
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 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 378.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 383.
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.

5 Calibration
Continued
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.
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 407.

5 Calibration
5.3.2 Updating revolution counters on OmniCore robots
Introduction
This section describes how to do a rough calibration of each manipulator axis by
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 378.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 386.
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.
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
(OmniCore).
Action
1 On the start screen, tap Calibrate.
The calibration summary page for the mechanical unit is displayed.
2 In the Calibration Methods menu, select Revolution Counters.

5 Calibration
Continued
Action
3 In the Selection column select the axes for which revolution counters need to be up-
dated.
4 Tap Update.
A dialog box is displayed warning that the updating operation cannot be undone.
5 Tap OK to update the revolution counter.
6
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 407.

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:
1 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.
2 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.
3 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.
Note
When calibrating the robot with the reference calibration routine, the robot must
be dressed with the same tools, process cabling and any other equipment as
when the reference values were created.
Note
When using reference calibration with some tools, typically large or flexible tools,
oscillations in the robot can cause issues leading to failure of the calibration.
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
Validation
In the mentioned routines, it is also possible to validate the calibration data.
Position of robot axes

The robot axes should be positioned close to 0 degrees before commencing the
calibration program. The axis chosen for calibration is then automatically run by
the calibration program to its exact calibration position during the calibration
procedure.

5 Calibration
Continued
It is possible to position some of the other axes in positions different from 0 degrees.
Information about which axes are allowed to be jogged is given on the FlexPendant.
These axes are marked with Unrestricted in the FlexPendant window. Also the
following table shows the dependencies between the axes.
Requirements for axis positioning during calibration
Axis to calibrate
Required Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6
position of
axis
Axis 1 - * * * * *
Axis 2 0 - 0 * * *
Axis 3 0 0 - * * *
Axis 4 * * * - 0 0
Axis 5 * * * * - 0
Axis 6 * * * * * -
- Axis to be calibrated
* Unrestricted. Axis is allowed to be jogged to other position than 0 degrees.
0 Axis must be put in position 0 degrees.
System containing SafeMove

SafeMove will lose its synchronization to the controller if a new calibration is done.
New calibration values have to be downloaded to SafeMove, and a new SafeMove
calibration has to be done. Make sure that the user rights admit to change the
safety settings and to synchronize SafeMove.
For robots with EPS, the same applies as for SafeMove.
How to calibrate a suspended robot

The IRB 4600 is fine 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.
The calibration tool will eventually break from fatigue after longer period of use
and then needs to be replaced. There is no risk for bad calibrations as long as the
calibration tool is in one piece.
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, 3HAC074119-001 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

This section shows how the robot is equipped with items for installation of
calibration tools for Axis Calibration (fixed calibration pins and/or bushings).
Installed calibration tools are not shown.
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.
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 3HAC074119-001 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.
After the calibration method has been started 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 389.
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 robot's 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
Action Note
3 Check if the standard calibration data for axes 4, If the data is optimized, the calibra-
5 or 6 are updated with wrist optimization. tion routine Wrist Optimization
This is shown in the calibration overview/summary must be re-run after standard calib-
window on the FlexPendant. ration.
See Calibrating with Wrist Optimiza-
tion method on page 404.
Starting the calibration procedure

Use this procedure to start the Axis Calibration routine on the FlexPendant.
Action Note
1 Tap the calibration icon and enter the calibration
main page.
2 All mechanical units connected to the system are
shown with their calibration status.
Tap the mechanical unit in question.
Note
For RobotWare 7, the mechanical unit page is

displayed only if there is more than one mechan-
ical unit available.
3 The calibration method used at ABB factory for The FlexPendant will give all inform-
each axis is shown, as well as calibration method ation needed to proceed with Axis
used for the robot during last field calibration. Calibration.
4 Valid for RobotWare 6
Tap Call Calibration Method. The software will
automatically call for the procedure for the valid
calibration method. If not, tap Call Routine and
then tap Axis calibration.
5 Valid for RobotWare 7
Tap Calibration Methods on the right pane and
then tap Calibration. The software will automatic-
ally call for the procedure for the valid calibration
method.
6 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 396.
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.

5 Calibration
Continued
Situation Action
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.
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 381
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.
However, SafeMove may generate other warning messages anytime during the
Axis Calibration routine. When a warning message is displayed, tap Acknowledge
to confirm the unsynchronized state and continue Axis Calibration procedure.
CAUTION
SafeMove must be synchronized after the calibration is completed.
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
6 If the standard calibration data for axes 4, 5 or 6 See Calibrating with Wrist Optimiz-
should be updated with wrist optimization, run the ation method on page 404.
calibration routine Wrist Optimization.

5 Calibration
5.4.5 Reference calibration
Brief introduction to Reference Calibration

Reference calibration is a faster method compared to Fine calibration, as it refers
to a previously made calibration.
1 Create a backup of the current robot system.
2 Check that the active calibration offset values corresponds to the values on
the calibration label (located on the lower arm or the base).
3 Jog the manipulator so that all axes are in zero position (ex use MoveAbsJ
instruction). Check that all axis scales are aligned with calibration marks.
4 If the scales differ from calibration marks it might depend on wrong turns of
the revolution counters. Make a marker line on the corresponding axis to be
able to validate the result of the calibration. If more than one motor revolutions
are wrong, the calibration will fail.
5 Use a verification position. This is especially recommended if all axes were
not aligned with the synchronization marks (step 3). Reuse an existing
position that is suitable and accurate so it can be used to validate the repair.
Use a position where a deviation in axis calibration gives a big deviation in
positioning. Note! Check the position after each repair in one axis.
6 Use Reference calibration to save reference values for all axes that is to be
replaced. Make sure that the values are saved in RobotStudio or FTP program.
The files are located in "Active system folder name/HOME/RefCalibFiles".
7 Perform the repair.
8 Make sure that the tooling and process equipment are the same as when
creating the reference. Use Reference calibration to update the system with
new calibration offset value for the repaired axis.
9 Check the position against the verification position (step 5).
10 Proceed with the repair of the next axis, if necessary, and repeat (step 8-9)
for every axis.
11 (For system containing SafeMove or EPS) Download new calibration values
to SafeMove. Use Visual SafeMove in RobotStudio.(For system containing
SafeMove) Download new calibration values to SafeMove. Use Visual
SafeMove in RobotStudio.
12 (For system containing SafeMove or EPS) Synchronize SafeMove to activate
SafeMove.(For system containing SafeMove) Synchronize SafeMove to
activate SafeMove.
13 Perform test run.
14 Update the calibration label with new resolver values (calibration values).
Manual tuning of calibration offset

Manual tuning of calibration offset is normally not needed, but can be useful in
some situations. The requirement to do manual tuning is that there is a known
accurate position, that worked accurately before the repair (step 5, see Brief
introduction to Reference Calibration on page 401).

5 Calibration
Continued
Example "Adjust axis 4":

1 Create a backup.
2 Run the manipulator to the verification position. (The manipulator position
is now deviating from the verification position.)
3 Read and note current axis 4 value in degrees (example: 96.3 degrees).
4 Manually jog, only axis 4, so that the manipulator is correctly positioned to
the verification position.
5 Read and note current axis 4 value in degrees (example: 94.2 degrees).
6 Move the manipulator to its calibration position.
7 Calculate the angle difference (ie 96.3-94.2=2.1 degrees).
8 Manually jog axis 4 the calculated angle difference (-2.1). NOTE! The direction
+/- shall be the same direction as the direction used when axis 4 was manually
jogged to coincide with the verification process. In the example -2.1 degrees.
9 Make a new manual fine calibration of axis 4 with axis in -2.1 degrees position.
10 Check again against the verification position.
11 Repeat the manual tuning if needed.
12 Create a new reference if the intention is to use the reference in the future.

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 Calibrating with Wrist Optimization method
When to run Wrist Optimization

Wrist Optimization routine is run to improve TCP reorientation performance.
Calibrating the robot with standard calibration method overwrites the optimized
positions of axes 4, 5, 6. Re-run the Wrist Optimization routine after standard
calibration to re-achieve the optimized positions of the wrist axes.
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 Wrist Optimization.
2 Modify targets for 4-point tool frame definition, in Wrist Optimization routine.
Tip
Select positions with large reorientations around the TCP. For best results,
make sure that axis 4 and 5 have large movements.
a Jog the robot to an appropriate position,
A, for the first approach point.
Use small increments to accurately posi-
tion the tool tip as close to the reference
point as possible.
b Tap Modify Position to define the point.
c Repeat for each approach point to be
defined, positions B, C, and D.
Jog away from the fixed world point to
achieve the best result. Just changing the
tool orientation will not give as good a
result.
en0400000906
3 Improved calibration data to the wrist axes is identified and presented.

4 Optimized positions for the wrist axes are presented.

5 Calibration
Continued
5 The robot moves to the optimized positions for the wrist axes and
automatically overwrites previous calibration data.
WARNING
Robot moves automatically when pressing Calibrate.
6 Wrist optimization is finished.

7 Redefine / verify TCP for all tools.

5 Calibration
5.7 Verifying the calibration
5.7 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 407.
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 378.
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.

5 Calibration
5.8 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 the Jog 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 378 and Updating revolution
counters on page 382.
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 378 and
date the revolution counters. Updating revolution counters on page 382.

5 Calibration
Continued
Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 Tap Code.
2 Create a new program.
3 Use MoveAbsJ in the Add Instruction 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 378 and Updating revolution
counters on page 382.
Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.
Action Note
1 Tap Jog.
2 From the Mechanical unit list select a
mechanical unit.
3 From the Motion mode section, select an
axis-set that need to be jogged.
For example, to jog axis 2, select the axis
set Axis 1-3.
4 Follow the screen instruction on joystick
movements to understand the direction of
the axis that you want to move and move
the joystick.
5 Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
6 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 378 and
date the revolution counters. Updating revolution counters on page 382.

6 Decommissioning
6.1 Introduction to decommissioning
6 Decommissioning
6.1 Introduction to decommissioning
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.
Note
The decommissioning process shall be preceded by a risk assessment.
Disposal of materials used in the robot

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.
See also Environmental information on page 410.
Transportation
Prepare the robot or parts before transport, this to avoid hazards.

6 Decommissioning
6.2 Environmental information
Introduction
ABB robots contain components in different materials. During decommissioning,
all materials should be dismantled, recycled, or reused responsibly, according to
the relevant laws and industrial standards. Robots or parts that can be reused or
upcycled helps to reduce the usage of natural resources.
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Materials used in the product

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
Aluminium Covers, synchronization brackets

Batteries, Lithium Serial measurement board
Cast iron/nodular iron Base, lower arm, upper arm
Copper Cables, motors
Neodymium Brakes, motors
Nickel Turning disc (foundry)
Oil, grease Gearboxes
Plastic/rubber Cables, connectors, drive belts, and so on.
Steel Gears, screws, base frame, and so on.

6 Decommissioning
Continued
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
Note
The decommissioning process shall be preceded by a risk assessment.
Important when scrapping the robot
DANGER
The risk assessment should consider hazards arising in the decommissioning,

such as, but not limited to:
• Always remove all batteries. 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.
• A used robot does not have the same performance as on delivery. Springs,
brakes, bearings, and other parts might be worn or broken.

7 Robot description
7.1 Manipulator types and variants
7 Robot description
7.1 Manipulator types and variants
Overview
IRB 4600 variant First manipulator revi- Second manipulator Third manipulator re- Fourth manipu-
sion (Type A) revision (Type B) vision (Type C) lator revision
(Type D)
IRB 4600-60/2.05, Axis 3 new gearbox Axis 3 new gearbox Axis 1 and 3 new
IRB 4600-45/2.05, gearboxes
IRB 4600-40/2.55
(Standard, Foundry
Plus 2)
IRB 4600-20/2.50 Axis 3 new gearbox Axis 3 new gearbox Axis 1 and 3 new Axis 4, 5, and 6
(Standard, Foundry gearboxes new motors
Plus 2)
IRB 4600-60/2.05, Axis 1 and 3 new
IRB 4600-40/2.55 gearboxes
(Clean Room)

7 Robot description
7.2 Type C of IRB 4600
7.2 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.

7 Robot description
7.3 Type D of IRB 4600
7.3 Type D of IRB 4600
Type D - alternative motor

Type D of IRB 4600 uses a Type C of IRB 4600 on page 414 with an alternative
motor, and is only valid for the 20 kg/2.50 m variant.

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
8.2 Applicable standards
General
The product is compliant with ISO 10218-1:2011, Robots for industrial environments
- Safety requirements - Part 1 Robots, and applicable parts in the normative
references, as referred to from ISO 10218-1:2011. In case of deviation from ISO
10218-1:2011, these are listed in the declaration of incorporation. The declaration
of incorporation is part of the delivery.
Robot standards
Standard Description
ISO 9283 Manipulating industrial robots – Performance criteria and re-
lated test methods
ISO 9787 Robots and robotic devices – Coordinate systems and motion
nomenclatures
ISO 9946 Manipulating industrial robots – Presentation of characteristics
Other standards used in design
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements, normative reference from ISO 10218-
1
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
standards – Emission standard for industrial environments
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design, normative reference
from ISO 10218-1
Region specific standards and regulations
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 434-03 Industrial robots and robot Systems - General safety require-
ments
EN ISO 10218-1 Robots and robotic devices — Safety requirements for indus-
trial robots — Part 1: Robots

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 ABB
robots.
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. It is recommended by ABB for M6-M20 screw joints. 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.
Generally, screws are lubricated with Gleitmo 603 mixed with Geomet 500 or
Geomet 702 in proportion 1:3. Geomet thickness varies according to screw
dimensions, refer to the following.
Dimension Lubricant Geomet thickness
M6-M20 (any length except Gleitmo 603 + Geomet 500 3-5 μm
M20x60)
M6-M20 (any length except Gleitmo 603 + Geomet 720 3-5 μm
M20x60)
M20x60 Gleitmo 603 + Geomet 500 8-12 μm
M20x60 Gleitmo 603 + Geomet 720 6-10 μm
Screws lubricated in other ways

Screws lubricated with Molykote 1000 or Molykote P1900 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.

8.4 Screw joints
Continued
Lubricant Article number

Molykote 1000 (molybdenum disulphide grease) 3HAC042472-001
Molykote P1900 (molybdenum disulphide grease) 3HAC070875-001
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.
• 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%!
Tightening torque for 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.
Note
A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.
Tightening torque for oil-lubricated screws with allen head screws

oil-lubricated screws with allen head screws.
Note

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

8.4 Screw joints
Continued
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
M24 680 960 1150
Tightening torque for lubricated screws (Molykote, Gleitmo or equivalent) with allen head screws
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M5 8
M6 14
M8 28 35
M10 55 70
M12 96 120
M16 235 300
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

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 arm weighs 25 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 424, 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
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- 3HAC074119- 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 B, C and
Type D.

8.7 Special tools
Continued

Turning tool (includes lifting instruction 3HAC048502-001 Valid for Types B, D
3HAC051688-001) and Type D.
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
Special tools
This table specifies the special tools required during several of the service
procedures. The tools are specified directly in concerned instructions.
Description Qty Article no.
Guide for reduction gear 1 3HACxxx
Used to guide axis-1 gear and frame
during refitting.

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.
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 for registered users on myABB Business Portal,
www.abb.com/myABB.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.

10 Circuit diagram
10.1 Circuit diagrams
10 Circuit diagram
Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.abb.com/myABB.
See the article numbers in the tables below.
Controllers
Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Manipulators

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 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001
3HAC029940-001

10 Circuit diagram
Continued

Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005
3HAC025744-001
Circuit diagram - IRB 910SC 3HAC056159-002

Index
Index D
direction of axes, 381
A E
Absolute Accuracy, calibration, 376 environmental information, 410
allergenic material, 32 ESD
aluminum damage elimination, 56
disposal, 410 sensitive equipment, 56
ambient humidity expansion container
operation, 48 installing, 95
storage, 47 expected life, 115
ambient temperature
operation, 48 F
storage, 47 fire extinguishing, 33
assembly instructions, 43 FlexPendant
assessment of hazards and risks, 32 jogging to calibration position, 407–408
Axis Calibration, 388 MoveAbsJ instruction, 407–408
calibration tool updating revolution counters, 383, 386
article number, 391, 396 foundation
examining, 391 requirements, 47
installation position, 393 free space above robot, 57
overview of method, 388
procedure on FlexPendant, 396, 404 G
protective cover and protection plug, 393, 396 gearboxes
location of, 155
B Gravity Alpha, 71
batteries Gravity Beta, 70
disposal, 410 grease, 36
battery pack disposal, 410
replacing, interval, 114
brakes H
testing function, 40 hanging
installed hanging, 32
C hazard levels, 23
cabinet lock, 33 hazardous material, 410
cabling, robot, 103 height
cabling between robot and controller, 102 installed at a height, 32
calibrating hot surfaces, 36
robot, 388 HRA, 32
roughly, 382, 386 humidity
calibrating robot, 388, 403–404 operation, 48
calibration storage, 47
Absolute Accuracy type, 374
rough, 382, 386 I
standard type, 374 instructions for assembly, 43
verification, 406 integrator responsibility, 32
when to calibrate, 377 intervals for maintenance, 113
calibration, Absolute Accuracy, 376
calibration manuals, 376 L
calibration marks, 378 labels
Calibration Pendulum robot, 25
overview of method, 403 leak-down test, 204
calibration position lifting
jogging to, 407–408 accessory, 62
scales, 378 lifting accessory, 423
calibration scales, 378 limitation of liability, 21
CalibWare, 374 Lithium
carbon dioxide extinguisher, 33 disposal, 410
cast iron loads on foundation, 46
disposal, 410 lock and tag, 33
cleaning, 197 lubricants, 36
climbing on robot, 36 lubrication
Cold environments, 101 amount in gearboxes, 155
connecting the robot and controller, cabling, 102 type of lubrication, 155
copper
disposal, 410 M
magnesium

Index
disposal, 410 S
maintenance schedule, 113 safety
MoveAbsJ instruction, 407–408 brake testing, 40
ESD, 56
N fire extinguishing, 33
national regulations, 32 release robot axes, 39
negative directions, axes, 381 signals, 23
neodymium signals in manual, 23
disposal, 410 symbols, 23
nodular iron symbols on robot, 25
disposal, 410 test run, 110
safety devices, 33
O safety hazard
oil, 36 hydraulic system, 34
amount in gearboxes, 155 pneumatic system, 34
disposal, 410 safety signals
type of oil, 155 in manual, 23
oil change safety standards, 418
axis 1, floor mounted robots, 157 scales on robot, 378
axis 1, suspended robots, 162 schedule for maintenance, 113
axis 2, 168 screw joints, 420
axis 3, 172 shipping, 409
axis 4, 179 signals
axis 5, 183 safety, 23
axis 6, 183 special tools, 425
operating conditions, 48 speed
options adjusting, 101
expansion container, 95 stability, 54
original spare parts, 21 standards, 418
ANSI, 418
P CAN, 418
pedestal start of robot in cold environments, 101
installed on pedestal, 32 steel
personnel disposal, 410
requirements, 22 storage conditions, 47
plastic suspended mounting, 70
disposal, 410 symbols
positive directions, axes, 381 safety, 23
PPE, 22 synchronization position, 382, 386
product standards, 418 sync marks, 378
protection classes, 48 system integrator requirements, 32
protection type, 48 system parameter
protective equipment, 22 Gravity Alpha, 71
protective wear, 22 Gravity Beta, 70
R T
recycling, 410 temperatures
regional regulations, 32 operation, 48
release brakes, 39 storage, 47
replacements, report, 203 testing
report replacements, 203 brakes, 40
requirements on foundation, 47 tilted mounting, 70
responsibility and validity, 21 tools
revolution counters Axis Calibration, 426
storing on FlexPendant, 383, 386 calibration equipment, Levelmeter, 425
updating, 382, 386 Calibration Pendulum, 426
risk of burns, 36 for service, 425
risk of tipping, 54 torques on foundation, 46
robot transportation, 409
labels, 25 troubleshooting
protection class, 48 oil spills, 197
protection types, 48 safety, 41
symbols, 25 turning
rubber accessory, 62
disposal, 410
U
upcycling, 410

Index
updating revolution counters, 382, 386 base, 266–267

users robot, 60, 68, 263, 287, 289, 295, 298, 312–313, 344,
requirements, 22 348, 356, 358, 367–369
upper and lower arm, 355, 359
V upper arm, complete, 277, 282
validity and responsibility, 21 Wrist Optimization
velocity overview of method, 404
adjusting, 101
verifying calibration, 406 Z
zero position
W checking, 407
weight, 45

ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 10-732 50 00
ABB AS
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Engineering (Shanghai) Ltd.

No. 4528 Kangxin Highway
PuDong New District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
ABB Inc.
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
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ROBOTICS

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© Copyright 2009-2023 ABB. All rights reserved.

© Copyright 2009-2023 ABB. All rights reserved.

2 Installation and commissioning 43

Product manual - IRB 4600 5

6 Product manual - IRB 4600

4.7.2 Refitting motors ...................................................................................... 329

7 Robot description 413

8 Reference information 417

9 Spare part lists 429

10 Circuit diagram 431

Product manual - IRB 4600 7

Overview of this manual

Product manual scope

It is the responsibility of the integrator to conduct a risk assessment of the final

Who should read this manual?

Continues on next page

• be trained to respond to emergencies or abnormal situations.

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Product manual - IRB 4600 17

All documents can be found via myABB Business Portal, www.abb.com/myABB.

Technical reference manuals

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• Examples of how to use the application.

Product manual - IRB 4600 19

How to read the product manual

References to required equipment

20 Product manual - IRB 4600

1.1.1 Limitation of liability

Spare parts and equipment

Product manual - IRB 4600 21

1.1.2 Requirements on personnel

Personal protective equipment

22 Product manual - IRB 4600

1.2 Safety signals and symbols

1.2.1 Safety signals in the manual

Introduction to safety signals

WARNING Signal word used to indicate a potentially hazardous

ELECTRICAL Signal word used to indicate a potentially hazardous

CAUTION Signal word used to indicate a potentially hazardous

ELECTROSTATIC Signal word used to indicate a potentially hazardous

NOTE Signal word used to indicate important facts and

Continues on next page

Symbol Designation Significance

24 Product manual - IRB 4600

1.2.2 Safety symbols on manipulator labels

Symbols on safety labels

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Before disassembly, see product manual

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