3HAC039842 PM IRB 460-En

ROBOTICS
Product manual
IRB 460
Trace back information:
Workspace 21D version a15
Checked in 2021-12-16
Skribenta version 5.4.005
Product manual
IRB 460 - 110/2.4
IRC5
Document ID: 3HAC039842-001

Revision: U
© Copyright 2012-2021 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 .................................................................................................................... 14
How to read the product manual ...................................................................................................... 16
1 Safety 17
1.1 Safety information ............................................................................................. 17
1.1.1 Limitation of liability ................................................................................. 17
1.1.2 Requirements on personnel ...................................................................... 18
1.2 Safety signals and symbols ................................................................................. 19
1.2.1 Safety signals in the manual ...................................................................... 19
1.2.2 Safety symbols on manipulator labels ......................................................... 21
1.3 Robot stopping functions .................................................................................... 27
1.4 Installation and commissioning ............................................................................ 28
1.5 Operation ........................................................................................................ 31
1.6 Maintenance and repair ...................................................................................... 32
1.6.1 Maintenance and repair ............................................................................ 32
1.6.2 Emergency release of the robot axes .......................................................... 35
1.6.3 Brake testing .......................................................................................... 36
1.7 Troubleshooting ................................................................................................ 37
1.8 Decommissioning .............................................................................................. 38
2 Installation and commissioning 39

2.1 Introduction to installation and commissioning ....................................................... 39
2.2 Unpacking ....................................................................................................... 40
2.2.1 Pre-installation procedure ......................................................................... 40
2.2.2 Working range and type of motion .............................................................. 44
2.2.3 Risk of tipping/stability ............................................................................. 46
2.2.4 The unit is sensitive to ESD ....................................................................... 47
2.3 On-site installation ............................................................................................ 48
2.3.1 Lifting the robot with fork lift accessory ....................................................... 48
2.3.1.1 Fitting the fork lift accessory .......................................................... 48
2.3.1.2 Lifting the robot with fork lift truck ................................................... 51
2.3.2 Lifting robot with roundslings .................................................................... 54
2.3.3 Manually releasing the brakes ................................................................... 56
2.3.4 Lifting the base plate ................................................................................ 58
2.3.5 Securing the base plate ............................................................................ 59
2.3.6 Orienting and securing the robot ................................................................ 64
2.3.7 Fitting equipment on robot ....................................................................... 68
2.3.8 Loads fitted to the robot, stopping time and braking distances ......................... 72
2.3.9 Installation of signal lamp, upper arm (option) .............................................. 73
2.4 Installation of options ......................................................................................... 77
2.4.1 Option 87-1 - Installing the cooling fan for axis-1 motor .................................. 77
2.5 Restricting the working range .............................................................................. 83
2.5.1 Introduction ............................................................................................ 83
2.5.2 Mechanically restricting the working range of axis 1 ...................................... 84
2.6 Robot in cold environments ................................................................................. 86
2.6.1 Start of robot in cold environments ............................................................ 86
2.7 Electrical connections ........................................................................................ 87
2.7.1 Robot cabling and connection points .......................................................... 87
2.7.2 Customer connectors on the manipulator .................................................... 90
3 Maintenance 93
3.1 Introduction ...................................................................................................... 93
3.2 Maintenance schedule and expected component life ............................................... 94
3.2.1 Specification of maintenance intervals ........................................................ 94
3.2.2 Maintenance schedule ............................................................................. 95
Product manual - IRB 460 5

3HAC039842-001 Revision: U
Table of contents
3.2.3 Expected component life .......................................................................... 97

3.3 Inspection activities ........................................................................................... 98
3.3.1 Inspecting the oil level in axis-1 gearbox ..................................................... 98
3.3.2 Inspecting, oil level gearbox axes 2 - 3 ....................................................... 100
3.3.3 Inspecting, oil level gearbox axis 6 ............................................................ 103
3.3.4 Inspecting, cable harness ........................................................................ 105
3.3.5 Inspecting the information labels ................................................................ 107
3.3.6 Inspecting the axis-1 mechanical stop pin ................................................... 109
3.3.7 Inspecting the additional mechanical stops ................................................. 111
3.3.8 Inspection, dampers ................................................................................ 113
3.3.9 Inspecting the signal lamp (option) ............................................................. 115
3.4 Replacement/changing activities .......................................................................... 117
3.4.1 Type of lubrication in gearboxes ................................................................ 117
3.4.2 Changing oil, axis-1 gearbox ..................................................................... 118
3.4.3 Changing oil, gearbox axes 2 and 3 ........................................................... 122
3.4.4 Changing oil, gearbox axis 6 ..................................................................... 126
3.4.5 Replacing the SMB battery ........................................................................ 128
3.5 Cleaning activities ............................................................................................. 132
3.5.1 Cleaning the IRB 460 ............................................................................... 132
4 Repair 135
4.1 Introduction ...................................................................................................... 135
4.2 General procedures ........................................................................................... 136
4.2.1 Performing a leak-down test ...................................................................... 136
4.2.2 Mounting instructions for bearings ............................................................. 137
4.2.3 Mounting instructions for sealings .............................................................. 139
4.2.4 Cut the paint or surface on the robot before replacing parts ............................ 142
4.2.5 The brake release buttons may be jammed after service work ......................... 143
4.3 Complete robot ................................................................................................. 144
4.3.1 Replacing cable harness, lower end (axes 1-3) ............................................. 144
4.3.2 Replacing the cable harness, upper end (incl. axis 6) ..................................... 154
4.3.3 Replacing customer cable harness (optional) ............................................... 161
4.3.4 Replacing the SMB unit ............................................................................ 171
4.3.5 Replacing the brake release board ............................................................. 176
4.3.6 Replacing the base, including axis 1 gearbox ............................................... 180
4.4 Upper and lower arm ......................................................................................... 189
4.4.1 Replacing the turning disk ........................................................................ 189
4.4.2 Replacing the tilthouse unit ....................................................................... 195
4.4.3 Replacing the upper arm .......................................................................... 216
4.4.4 Replacing linkage - upper link arm .............................................................. 233
4.4.5 Replacing linkage - lower link arm .............................................................. 241
4.4.6 Replacing the linkage - link ....................................................................... 248
4.4.7 Replacing the POM sealing for the link system ............................................. 264
4.4.8 Replacing parallel rod .............................................................................. 265
4.4.9 Replacing the complete lower arm system ................................................... 275
4.4.10 Replacing the parallel arm ........................................................................ 285
4.5 Motors ............................................................................................................ 293
4.5.1 Replacing motor, axis 1 ............................................................................ 293
4.5.2 Replacing motors, axes 2 and 3 ................................................................. 300
4.5.3 Replacing motor, axis 6 ............................................................................ 312
4.6 Gearboxes ....................................................................................................... 320
4.6.1 Replacing the axis 1 gearbox ..................................................................... 320
4.6.4 Replacing gearbox axis 6 .......................................................................... 344
5 Calibration 353
5.1 Introduction to calibration ................................................................................... 353
5.1.1 Introduction and calibration terminology ...................................................... 353
6 Product manual - IRB 460

Table of contents
5.1.2 Calibration methods ................................................................................. 354

5.1.3 When to calibrate ................................................................................... 356
5.2 Synchronization marks and axis movement directions ............................................. 357
5.2.1 Synchronization marks and synchronization position for axes ......................... 357
5.2.2 Calibration movement directions for all axes ................................................ 358
5.3 Updating revolution counters ............................................................................... 359
5.3.1 Updating revolution counters on IRC5 robots ............................................... 359
5.4 Calibrating with Axis Calibration method ............................................................... 363
5.4.1 Description of Axis Calibration .................................................................. 363
5.4.2 Calibration tools for Axis Calibration ........................................................... 366
5.4.3 Installation locations for the calibration tools ............................................... 368
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 370
5.4.5 Reference calibration ............................................................................... 373
5.5 Calibrating with Calibration Pendulum method ....................................................... 375
5.6 Verifying the calibration ...................................................................................... 376
5.7 Checking the synchronization position .................................................................. 377
6 Decommissioning 379
6.1 Environmental information .................................................................................. 379
6.2 Scrapping of robot ............................................................................................. 381
7 Reference information 383

7.1 Introduction ...................................................................................................... 383
7.2 Applicable standards ......................................................................................... 384
7.3 Unit conversion ................................................................................................. 386
7.4 Screw joints .................................................................................................... 387
7.5 Weight specifications ......................................................................................... 390
7.6 Standard tools .................................................................................................. 391
7.7 Special tools .................................................................................................... 392
7.8 Lifting accessories and lifting instructions .............................................................. 396
8 Spare parts 397

8.1 Spare part lists and illustrations ........................................................................... 397
9 Circuit diagrams 399

9.1 Circuit diagrams ................................................................................................ 399
Index 401

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Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The manual also contains reference information for all procedures detailed in the
manual.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope

The manual covers covers all variants and designs of the IRB 460. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information about how to avoid
personal injuries and damage to the product.
Installation and com- Required information about lifting and installation of the robot.
missioning
Maintenance Step-by-step procedures that describe how to perform maintenance
of the robot. Based on a maintenance schedule that may be used
in the work of planning periodical maintenance.
Continues on next page

Continued
Chapter Contents
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration Calibration procedures and general information about calibration.
Decommissioning Environmental information about the robot and its components.
Reference information Useful information when performing installation, maintenance or
repair work. Includes lists of necessary tools, additional documents,
safety standards etc.
Spare part list Reference to the spare part list for the robot.
Circuit diagram Reference to the circuit diagram for the robot.
References
Reference Document ID
Product manual, spare parts - IRB 460 3HAC040628-001
Product specification - IRB 460 Document.ID-1
Safety manual for robot - Manipulator and IRC5 or OmniCore 3HAC031045-001
controller i
Product manual - IRC5 3HAC021313-001
IRC5 with main computer DSQC 639.
Product manual - IRC5 3HAC047136-001
IRC5 with main computer DSQC1000.
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - Service Information System 3HAC050944-001
Application manual - Electronic Position Switches 3HAC050996-001
Application manual - Additional axes and stand alone con- 3HAC051016-001
troller
Technical reference manual - Lubrication in gearboxes 3HAC042927-001
Technical reference manual - System parameters 3HAC050948-001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
Revision Description
- First edition.
A This revision includes the following updates:
• Added safety section, Signal lamp (optional).
• A new block, about general illustrations, added in section How to read
the product manual on page 16.
• Illustrations improved throughout the Repair chapter.
• Method of replacing the base updated and bits holder added in section
Replacing the base, including axis 1 gearbox on page 180.
• Refitting method updated in section Replacing the turning disk.
• Re-calibration added in section Replacing the turning disk.
• Details about tools added in section Replacing the tilthouse unit on
page 195.

Continued
• Procedures for Removal and Refitting updated in section Replacing
the upper arm on page 216.
• Three legged bearing puller added in Required equipment sections
Replacing linkage - upper link arm on page 233 and Replacing linkage
- lower link arm on page 241.
• Replacing method updated in section Replacing motors, axes 2 and
3 on page 300.
• Text updated in section Replacing the axis 1 gearbox on page 320.
• In previous section Replacing the axis 2 and 3 gearboxes, replacing
gearbox axis 3 has been removed and now only describes the axis 2
gearbox.
• New section included Replacing the axis 3 gearbox.
• Changed the weight of the robot, see Weight, robot on page 40.
• Added an illustration that shows the directions of the robot stress
forces, see Loads on foundation, robot on page 41.
• Added new section about how to install the signal lamp, see Installation
of signal lamp, upper arm (option) on page 73.
• Added information that the working range of axis 1 also can be restric-
ted by EPS, see Introduction on page 83.
• Special tools updated.
B This revision includes the following updates:
• Minor corrections and editorial changes made throughout the manual.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 387.
• Added steps in the instruction for replacing upper end of cabling, see
Replacing the cable harness, upper end (incl. axis 6) on page 154.
• Added information about batteries.
C This revision includes the following updates:
• The maximum allowed deviation in levelness of the base plate is
changed, see Securing the base plate on page 59.
• Reference to Hilti standard added to the foundation recommendation
for the base plate and class designation for foundation is changed to
european standard C25/C30 (previously Swedish standard K25/K30),
see Securing the base plate on page 59.
• All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount of oil
in gearboxes on page 117.
• Added a new sealing structure that contains a support ring, o-ring and
radial sealing at the link, see Replacing the linkage - link on page 248
and Replacing the upper arm on page 216.
• Three o-rings are added to the equipment list and procedure in section
Replacing the axis 1 gearbox on page 320.
• A new SMB unit and battery is introduced, with longer battery lifetime.
D This revision includes the following updates:
• A new procedure is added to the manual: Option 87-1 - Installing the
cooling fan for axis-1 motor on page 77.
• The position of the battery holder for RMU lithium battery (3-pole
battery contacts) has changed. The figures and text has been updated.
E This revision includes the following updates:
• Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 381.
F This revision includes the following updates:
• New illustrations added for lower arm and lower and upper arm joints.

Continued
• The maximum allowed deviation in levelness of the base plate and
foundation is changed, see Securing the base plate on page 59.
• Minor corrections.
G This revision includes the following updates:
• Splitted instruction for fork lift accessory use in two sections.
• Illustrations of SMB battery RMU improved,
H This revision includes the following updates:
• Article number for label updated (Combined warning label "Brake re-
lease", "Brake release buttons" and "Moving robot")
J Published in release R16.2. The following updates are made in this revision:
• Drawing of base plate is not available for purchase, faulty information
removed in Securing the base plate on page 59.
• Corrections due to updates in terminology.
K Published in release R17.1. The following updates are made in this revision:
• Added labels to the robot, one warning label (A) on the axis-6 motor,
one battery label (N) and one stock robots label (P) See Inspecting
the information labels on page 107.
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 353.
L Published in release R17.2. The following updates are made in this revision:
• Caution about removing metal residues added in sections about SMB
boards.
• 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.
• Added text regarding overhaul in section specification of maintenance
intervals.
• Updated the section Start of robot in cold environments on page 86.
• Updated information regarding replacement of brake release board.
• Lifting robot with roundslings updated.
• Updated information regarding disconnecting and reconnecting battery
cable to serial measurement board.
M Published in release R18.1. The following updates are made in this revision:
• Information added about fatigue to Axis Calibration tool, see Calibration
tools for Axis Calibration on page 366.
• Added section, Cut the paint or surface on the robot before replacing
parts.
• New spare part numbers 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.
N Published in release R18.2. The following updates are done in this revision:
• Added locating hole position in tool flange view.
P Published in release R18.2. The following updates are done in this revision:
• Updated references.
Q 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 142.
• New article numbers for manipulator cables in section Robot cabling
and connection points on page 87.

Continued
• Changed the article number of special tools bits extension and lifting
accessory, motor axes 2-3 from 3HAC023760-001 and 3HAC14586-1
to 3HAC12342-1 and 3HAC15534-1, respectively.
• Added tightening torque of the shaft when refitting the upper arm.
• Updated the information of the hole for filling grease when refitting
the link.
R Published in release 19D. The following updates are made in this revision:
• Added press tool for installation of support rings in the upper arm
housing, see Replacing the upper arm on page 216.
S 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 139.
• Clarified text about position of robot 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.
T Published in release 21B. The following updates are made in this revision:
• New number and instruction for press tool, parallel arm, see Replacing
the parallel arm on page 285.
• New number and instruction for press tool, tilt house, see Replacing
the tilthouse unit on page 195.
• New number and instruction for press tool, linkage - link, see Replacing
the linkage - link on page 248.
• Text regarding fastener quality is updated, see Fastener quality on
page 71.
U Published in release 21D. The following updates are made in this revision:
• New section regarding customer connectors added, see Customer
connectors on the manipulator.
• Added replacement of customer cable harness, see Replacing cus-
tomer cable harness (optional) on page 161.

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/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with 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.
• Examples of how to use the application.

Continued
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 17.
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.
• 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. 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 21.
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
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 - IRC5
• Product manual - IRC5 Compact
• Product manual - IRC5 Panel Mounted Controller

1 Safety
1.4 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 379 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
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
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 Operation
1.5 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 Maintenance and repair
1.6 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 loose screws, turnings, or other unexpected parts
remaining after work on the robot has been performed.
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
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
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.

1 Safety
Continued
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 42.
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 56.
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 Troubleshooting
1.7 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 Decommissioning
1.8 Decommissioning
General
See section Decommissioning on page 379.
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
460 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.
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 17 before performing any installation
work.
Note
Always connect the IRB 460 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
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 40
6 If the robot is not installed directly, it must be stored as described in: Storage condi-
tions, robot on page 42
7 Make sure that the expected operating environment of the robot conforms to the
specifications as described in: Operating conditions, robot on page 42
8 Before taking the robot to its installation site, make sure that the site conforms to:
• Loads on foundation, robot on page 41
• Protection classes, robot on page 43
• Requirements, foundation on page 42
9 Before moving the robot, please observe the stability of the robot: Risk of tipping/sta-
bility on page 46
10 When these prerequisites are met, the robot can be taken to its installation site as
described in section: On-site installation on page 48
11 Install required equipment, if any.
• Installation of signal lamp, upper arm (option) on page 73
Weight, robot
The table shows the weight of the robot.
Robot model Weight
IRB 460 925 kg

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

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

Fz Force in the Z plane
Txy Bending torque in any direction in the XY plane
Tz Bending torque in the Z plane
The table shows the various forces and torques working on the robot during different
kinds of operation.
Note
These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
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 ± 6.2 kN ± 10.6 kN
Continued
Force Endurance load (in operation) Max. load (emergency stop)

Force z 10 ± 3.8 kN 10 ± 6.5 kN
Torque xy ± 13.7 kNm ± 23 kNm
Torque z ± 5.3 kNm ± 7.9 kNm
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 0.3 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.
Maximum tilt 5°
Minimum resonance 20 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)
Operating conditions, robot

The table shows the allowed operating conditions for the robot:
Parameter Value
Minimum ambient temperature 0°C i

Continued
Parameter Value
Maximum ambient temperature +45°C
Maximum ambient humidity 95% at constant temperature
i During cold start (0° C - 5° C), see Start of robot in cold environments on page 86.
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

2.2.2 Working range and type of motion
Working range
The following figures show the working ranges of the robot variants. The extreme
positions of the robot arm are specified at the wrist center (dimensions in mm).
IRB 460 - 110/2.4
xx1000001043
A Maximal working range

B Mechanical stop
C Maximal working range
D Tool flange center
Position in figure Position (mm) Angles (°)

X Z Axis 2 Axis 3
1 1505 1437 0 0
2 836 1565 -40 -20
3 802 782 -40 25
4 742 145 55 120
5 909 -314 85 120
6 2385 223 85 20
7 2111 1510 45 -20

Continued
Type of motion
The table below specifies the types and ranges of the robot motion in every axis.
Axis Type of motion Range of motion
1 Rotation motion -165° to +165°
2 Arm motion -40° to +85°
3 Arm motion -20° to +120°
2-3 Arm motion 25° to 155°
6 Turn motion -300° to +300°
Turning radius
xx1000001202
(A) Motor, axis 3

2.2.3 Risk of tipping/stability
2.2.3 Risk of tipping/stability
Risk of tipping
Do not change the robot position before securing it to the foundation.
The shipping position is the most stable position.
Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.
40°
25°
1707
692,5
94
627 380
773 907
xx1000001158
WARNING
The robot will be mechanically unstable if not properly secured to the foundation.

2.2.4 The unit is sensitive to ESD
2.2.4 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.

2.3.1.1 Fitting the fork lift accessory
2.3 On-site installation
2.3.1 Lifting the robot with fork lift accessory
Required equipment
The following equipment is required when lifting a robot with the fork lift accessory:
Equipment Art. no. Note
Fork lift pocket set 3HAC025040-003 The fork lift accessory set con-
tains:
• fork lift pocket
3HAC025528-001, with CE-
Marking fitted (4 pcs)
• attachment screws
M20x60 Steel 8.8-A3F (8
pcs)
• Drawing Fork lift accessory
set
• manual Directions for
use - Fork lift accessory for
IRB 6620, 6640, 460
Fork lift truck - The operator must be fully trained
and authorized to operate a fork
lift truck.
Preparations before fitting the fork lift pockets

Action Note
1 Remove any tools fitted on the axis-6 turning disk. DressPack, if used, can stay fitted
as long as the tool fitted on the
Note turning disk is removed.
No tool is permitted to be fitted on the robot when

lifting the robot with the fork lift accessory!
2 Jog the robot to its shipping position. See figures 40°

for the different IRB models.
Note
25°
The figures shows the shipping position of an

1707
undressed robot. If the robot is dressed, this must m
be taken into consideration when the robot is be-

ing lifted.
692,5
94
627 380
773 907
xx1000001158

Continued
Action Note
3
DANGER
Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.
Attachment points on the robot

The fork lift accessory is fitted on the robot as shown in the figure.
xx0600002910
A Fork lift pocket

B Attachment screw M20x60 quality 8.8 (2 pcs x4)

Continued
Fitting the fork lift accessory set

Action Note
1 Fit the four fork lift pockets on the base of the ro- Tightening torque: 300 Nm
bot with its attachment screws.
Note
Before fitting any attachment screws, make sure

they are not damaged in any way. Replace dam-
aged screws.
xx0600002930
A Fork lift pocket (4 pcs)

B Attachment screw M20x60
quality 8.8 (2 pcs x4)
2 Verify that all four fork lift pockets are properly
secured before lifting.

2.3.1.2 Lifting the robot with fork lift truck
General
The robot may be moved using a fork lift truck, provided that a complete fork lift
accessory set, aimed for the robot, is used.
This section describes how to lift the robot with a fork lift truck.
Required equipment

Fork lift accessory 3HAC025040-003
Fork lift truck
Lifting the robot with fork lift truck
Action Note
1 Make sure that the robot is in shipping
position! Note
No load is permitted on the robot!
2
DANGER
Make sure that all supplies for electrical

power, hydraulic pressure, and air pres-
sure are turned off.
3 Verify that all four fork lift pockets are

properly secured before lifting.

Continued
Action Note
4 Insert fork lift forks into the pockets. IRB 6620
CAUTION
Lifting the robot with fork lift shall only be

done with all four fork lift pockets fitted!
If lifting with fewer than four fork lift
pockets fitted, there is a risk of accidents!
xx0600002911
IRB 6640
Ax3
10°
A x2 5
45° Ax0°
8
xx0600003401
IRB 460
xx1000001159

Continued
Action Note
5 Remove the attachment bolts securing
the robot to the foundation.
6
CAUTION
The IRB 460 robot weighs 925 kg.

All lifting accessories used must be sized
accordingly!
7 Carefully lift the robot.
WARNING
Personnel must not, under any circum-

stances, be present under the suspended
load!
8 Move the robot slowly to its new position.

Note
Move the robot with low speed!
9 Secure the robot to the foundation
DANGER
Do not power the robot up until it is se-

cured properly to the foundation.
10 Remove the fork lift accessories.

2.3.2 Lifting robot with roundslings
General
The robot can be lifted with roundslings according to this section.
Sling specification
Sling type Qty Lifting capacity Length / Note

Roundsling, robot 3 pcs 2 000 kg 2m
2 pcs 2 000 kg 2.5 m
Lifting with roundslings
Action Note
1 Position robot in a secure transport position. 40°
25°
m
xx1000001155
2 Attach lifting eye bolts in the rear M20 holes. Shown in figure Attachment points on
page 55.
3 Attach roundslings to robot according to fig-
ure Attachment points on page 55.
4
Note
Make sure that the roundslings do not lie

against sensitive parts, for example harness
and customer equipment!
5
CAUTION
The IRB 460 robot weighs 925 kg.

accordingly!
6
WARNING
Personnel must not, under any circum-

stances, be present under the suspended
load!

Continued
Attachment points
This figure shows how to attach the roundslings to the robot.
The illustration is similar with the label attached to the robot’s lower arm.
xx1000001156
A Lifting eye bolts M20 (2 pcs)

B Shackle (2 pcs). Lifting capacity: 2,000 kg.
C Roundsling, 2 m (2 pcs). Lifting capacity: 2,000 kg.
D Roundsling, 2.5 m (2 pcs). Lifting capacity: 2,000 kg. Wrap once!
E Roundsling, 2 m, secures against rotation. Lifting capacity: 2,000 kg. Wrap twice!

2.3.3 Manually releasing the brakes
Introduction to manually releasing the brakes

This section describes how to release the holding brakes for the motors of each
axis.
Location of brake release unit

The internal brake release unit is located as shown in the figure.
Note
Axes 4 and 5 do not exist!
xx1000001157
Releasing the brakes

This procedure details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
Action Note
1 The internal brake release unit is equipped with Buttons are shown in figure Loca-
buttons for controlling the axes brakes. The buttons tion of brake release unit on
are numbered according to the numbers of the page 56.
axes.
Note
Axes 4 and 5 do not exist!

If the robot is not connected to the controller, power
must be supplied to the connector R1.MP according
to the section Supplying power to connector R1.MP
on page 57.

Continued
Action Note
2
DANGER
When releasing the holding brakes, the robot axes

may move very quickly and sometimes in unexpec-
ted ways.
Make sure no personnel is near or beneath the ro-
bot.
3 Release the holding brake on a particular robot

axis by pressing the corresponding button on the
internal brake release unit.
The brake will function again as soon as the button
is released.
Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector
R1.MP on the robot, in order to enable the brake release buttons.
Action Note
1
DANGER
Incorrect connections, such as supplying

power to the wrong pin, may cause all
brakes to be released simultaneously!
2 Supply 0V on pin 12 and 24V on pin 11.
xx0600002937

2.3.4 Lifting the base plate
2.3.4 Lifting the base plate
Required equipment
Equipment Article number Note

Lifting eye, M16 3HAC14457-4 3 pcs
Lifting slings Length: approx. 2 m
Hole configuration
xx0200000096
A Attachment holes for lifting eyes (x3)
Lifting, base plate
Action Note
1
CAUTION
The base plate weighs 353 kg. All lifting accessories

used must be sized accordingly.
2 Fit lifting eyes in specified holes. Shown in figure Hole configur-

ation on page 58.
3 Fit lifting slings to the eyes and to the lifting accessory.
CAUTION
Lift and move the base plate very slowly. If the base
plate starts to swing it is a risk for injuries or damage.

2.3.5 Securing the base plate
Base plate, dimensions

D G H
2x R525
598,31
560,85
B 487,01
(Ø 8 455
00)
950
243,5
F 12x M24 A E
2x 450 Ø1 A
A
0
73,84
231,5
111,30
C C
560,85
634,68
502,04
73,84
0
132,64
317,3
2x 50x45º
857,3
1020
48
4x
(4x)
6,3
)
(48
(2 3x
) 45
º
0.3 Common Zone
E, F, G, H
13
1,6
A
(2)
1,6
)
(2
13
3x
A-A 45
Ø 45P7 º B-B
Ø1.5
47 +0
0 ,5
c
K7
3x R1
45
52,
0,25 c
5º
(2
) (2x R22,5)
4
3x
3x 90º 1,6
C-C D
xx1000001053
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact
surface to the other)

Continued
xx0400000715
A Four holes for alternative clamping, 4x Ø18

Continued
Base plate, orienting grooves and leveling bolts

The illustration below shows the orienting grooves and attachment holes for leveling
bolts in the base plate.
B A
B
B
A
xx1500000312
A Orienting grooves (3 pcs)

B Levelling bolts, attachment holes (4 pcs)

Continued
Base plate, guide sleeve holes

The illustration below shows the orienting grooves and guide sleeve holes in the
base plate.
xx0300000045
A Guide sleeve holes (2 pcs)
Required equipment

Base plate Includes
• guide sleeves, 3HAC12937-3
• levelling screws, 9ADA120-79
• attachment screws and washers
for securing the robot to the
base plate.
Standard toolkit - Content is defined in section Standard
tools on page 391.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.
Base plate
This section details how to secure the base plate to the foundation.
Action Note
1 Make sure the foundation is levelled.

Continued
Action Note
2
CAUTION
The base plate weighs 353 kg! All lifting

equipment used must be sized accordingly!
3 Position base plate in relation to the robot Shown in figure Base plate, orienting
work location using the grooves in the base grooves and leveling bolts on page 61.
plate.
4 Lift the base plate to its mounting position. Detailed in section Lifting the base plate
on page 58.
5 Use the base plate as a template and drill at- Attachment holes: 16 pcs.
tachment holes as required by the selected
bolt dimension.
6 Fit the base plate and use the levelling bolts Shown in figure Base plate, orienting
to level the base plate. grooves and leveling bolts on page 61.
7 If required, fit strips of sheet metal underneath
the base plate to fill any gaps.
8 Secure the base plate to the foundation with
screws and sleeves.
9 Recheck the four contact surfaces on the Maximum allowed deviation all over the
base plate to make sure the base plate is base plate, from one contact surface to
levelled and flat. the other: 0.3 mm.
If it is not, use pieces of sheet metal or similar
to bring the base plate to a levelled position.

2.3.6 Orienting and securing the robot
General
This section details how to orient and secure the robot to the base plate in order
to run the robot safely.
Illustration, robot fitted to base plate

This illustration shows the robot base fitted to the base plate.
xx0600002933
A Robot attachment bolts and washers, 8 pcs (M24 x 100)

B Orienting grooves in the robot base and in the base plate
C Levelling screws. Note! Remove before the robot base is fitted!
D Base plate attachment screws
Attachment screws
The table below specifies the type of securing screws and washers to be used for
securing the robot to the base plate/foundation.
Suitable screws, lightly lubricated: M24 x 100
Quality: Quality 8.8
Suitable washer: Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque: 725 Nm

Continued
Securing the robot

Use this procedure to secure robot to base plate after fitting plate to the foundation.
Action Note
1 Lift the robot. See section Lifting robot with round-
slings on page 54.
2 Move robot to the vicinity of its installation loca-
tion.
3 Fit two guide sleeves to the guide sleeve holes Shown in figure Base plate, guide
in the base plate. sleeve holes on page 62.
Note
One of the guide sleeve holes is

elongated!
4 Guide the robot gently using two M24 screws Make sure the robot base is correctly
while lowering it into its mounting position. fitted onto the guide sleeves!
5 Fit the bolts and washers in the base attach- Specified in Attachment screws on
ment holes. page 64.
Shown in figure Illustration, robot fitted
to base plate on page 64.
Note
Lightly lubricate screws before as-

sembly!
6 Tighten bolts in a criss-cross pattern to ensure

that the base is not distorted.

Continued
Hole configuration, base

This illustration shows the hole configuration used when securing the robot.
R400
4
x
15
°
4x3
7.5°
xx0600002932

Continued
Cross section, guide sleeve hole

This illustration shows the cross section of the guide sleeve holes.
xx0600002934

2.3.7 Fitting equipment on robot
General
The robot features mounting holes for additional equipment.
Note
All equipment and cables used on the robot, must be designed and fitted not to
damage the robot and/or its parts.
Illustration, fitting of extra equipment on upper arm

The illustration below shows the mounting holes available for fitting extra equipment
on the upper arm.
For mounting of an external vacuum hose there are six holes on the upper arm.
The maximum weight for the vacuum hose and fastening device is 35 kg.

Continued
Note! The weight of the extra equipment on the upper arm must be deducted from
the maximal handling capacity.
94
476 .3 °
50 6xM10
0.5
30
40
90
70
315.5
50
20
25
30 6xM8 9 (B)
40
200
50
40
200
D
M10 (2x75) (A)
M10 (2x82) (A)
M10 (2x85) (A)
xx1000001041
A M10 mounting holes on upper arm

B Drill depth 15 mm

Continued
Illustration, fitting on turning disk

The illustration below shows the mounting holes available for fitting equipment on
the turning disk.
xx1000001042
(B)
(A) X
xx1800001402
- Tool flange in bottom view

A Locating hole
B Tool coordinate system

Continued
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
Stopping time and braking distances

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

2.3.9 Installation of signal lamp, upper arm (option)
General
As an option, a signal lamp can be installed on the robot. The lamp is activated
when the controller is in the MOTORS ON state.
Location of signal lamp, upper arm

The signal lamp is located on the tilthouse unit, as shown in figure.
xx1000001287
A Signal lamp
B Attachment screw M6x8 (2 pcs)
C Motor cover
Required equipment
Equipment, etc. Article number Note

Signal lamp kit Spare parts on Complete kit with signal lamp,
page 397. cables, adapter, gasket, screws etc.
Gasket 3HAC033206-001 Fitted between motor and cable
gland, replace if damaged.
Standard toolkit Content is defined in section Stand-
ard tools on page 391.

Continued

Other tools and procedures may
be required. See references to
Signal lamp kit

Figure shows signal lamp kit on IRB 760.
B
x-x
x
x
F
xx1000001064
A Signal lamp bracket

B Attachment screws for the bracket, M8x12 (2 pcs)
C Attachment screws for the signal lamp (2 pcs)
D Cable straps (2 pcs)
E Cable gland cover
F Motor adapter including gasket
G Attachment screw, M6x40 (1 pc)

Continued
Installation, signal lamp

Use this procedure to install the signal lamp to the robot.
Action Note
1 Fit the signal lamp bracket to the tilthouse, with See figure Signal lamp kit on
two attachment screws. page 74.
2 Fit the signal lamp to the bracket, with two attach- See figure Signal lamp kit on
ment screws. (not applicable for IRB 760 - page 74.
445/3.2)
3 If not already connected, connect the signal lamp See Electrical installation, signal
to the axis 6 motor. lamp on page 75.
DANGER
Turn off all:

area.
4 Arrange the signal cable in a loop at the signal See figure Signal lamp kit on
cable bracket with two cable straps. page 74.
Electrical installation, signal lamp

Use this procedure to connect the signal lamp to the axis 6 motor. The instruction
requires that the signal lamp is already mounted to the tilthouse.
Action Note
1
DANGER
Turn off all:

area.
2 Remove the motor cover by unscrewing the four See figure Location of signal lamp,
attachment screws. upper arm on page 73.
3 Disconnect the motor connectors.

Continued
Action Note
4 Remove the cable gland cover at the cable exit See figure Signal lamp kit on
by removing the attachment screw. page 74.
Replace the screw with a longer one, when refit-
ting in following steps (enclosed in the signal
lamp kit).
xx0600002694
A Screw that holds the cable

gland
5 See how the adapter is going to be fitted to the Enclosed with signal lamp kit.
motor and then fit the gasket to the side of the
adapter that will be facing downwards. The gas-
ket will protect the mating surfaces of the adapter
and the cable gland cover.
6 Place gasket and motor adapter above the cable See figure Signal lamp kit on
gland cover and refit the complete package to page 74.
the motor. Secure with attachment screw M6x40, In addtion to the enclosed gasket that
enclosed with the signal lamp kit. is fitted to the adapter, there is also
a gasket located on the motor. Make
sure it does not get damaged. Re-
place if damaged!
7 Push the signal cable through the hole in the
adapter and connect it to the connector inside
the motor.
8 Loosen the motor cables at the glands and adjust
their lengths with + 20 mm into the motor.
9 Connect motor cables inside the motor.
10 Secure motor cables at cable gland again.
11 Fit the motor cover with the attachment screws.
Make sure the cabling is placed correctly when
refitting the cover and does not get jammed.

2.4.1 Option 87-1 - Installing the cooling fan for axis-1 motor
2.4 Installation of options
General
A cooling fan (option 87-1) can be installed on the axis-1 motor.
Location of cooling fan
xx1300000168

Continued
Illustration of cooling fan

The details of the cooling fan are shown in the figure below.
xx1300000763
A Fan box
B Attachment screws (16 pcs)
C Groove in the connector
D Tightening screws (3 pcs)
Required equipment

Cooling fan See Product manu-
al, spare parts - IRB
Fan axis-1 cable harness 460. Choose this if equipping the robot with a
cooling fan on the axis-1 motor.
Motor cover Choose this if equipping the robot with a
cooling fan on the axis-1 motor.

Continued

Locking liquid - Loctite 243. Used for the three tightening
screws.
tools on page 391.
Circuit diagram - See chapter Circuit diagrams on page 399.
Other tools and procedures These procedures include references to
may be required. See refer- the tools required.
ences to these procedures
in the step-by-step instruc-
tions below.
Installing the cooling fan
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 Disassemble the parts of the fan box by remov-

ing the attachment screws.
xx1300000843
3 Loosen the three tightening screws, to avoid

damaging the surfaces of the motor when fit-
ting the fan box.
xx1300000844

Continued
Action Note
4 Insert and turn the connector so that the
groove points inwards, as shown in the figure.
xx1300000764
5 Temporarily lift the motor cabling out of the

way to make room for the fan box.
6 Fit the parts of the fan box to the motor and
reassemble with the attachment screws.
7 Lift the fan box so that it does not rest directly
on the robot and secure the box with the three
tightening screws, using locking liquid. Tighten
them properly so that the box is firmly attached
to the motor.
8 Install the cabling and make adjustments in
RobotWare, as described in the following pro-
cedures.

Continued
Illustration of separate cable for the fan

The figure below shows the cabling used for the fan on axis 1.
xx1300000765
A Connector R3.FAN.
Connected to the fan box.
B Connector R2.FAN.
Connected to the robot cable harness.
C Screw M12x1.5.
Secures the cable to the motor cover.
Installing the separate cable for the fan

Action Note
1 Move the robot to its calibration position.
2
DANGER
Turn off all:

3 Insert the fan cable through the motor cover and

tighten the screw.
xx1300000766

Continued
Action Note
R2.FB1
4 Connect the connector R2.FAN to the connector
R2.FAN1 on the robot cable harness.
R2.MP1
R2.FAN1
xx1300000767
5 Fit the motor cover to the motor.
Note
Make sure to fit the motor cover at the correct

direction, see the figure.
6 Connect the connector R3.FAN to the connector

on the fan box.
7 Strap the cable onto the axis-1 motor cables (at
position A).
xx1300000768

2.5.1 Introduction
2.5 Restricting the working range
2.5.1 Introduction
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 axis may be restricted:
• Axis 1, hardware (mechanical stop) and software (EPS) .
As standard configuration, axis 1 is allowed to move ± 165º.
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.

2.5.2 Mechanically restricting the working range of axis 1
General
The working range of axis 1 is limited by fixed mechanical stops and adjustment
of the system parameter configuration. The working range can be reduced by
adding additional mechanical stops giving 7.5 or 15 graduation, between 22.5°
and 135° in both directions.
Mechanical stops, axis 1

The illustration shows the mounting position of the stop pin and one of the additional
mechanical stops available for axis 1.
The figure shows IRB 6640 but is also valid for IRB 460.
xx0600002938
A Movable mechanical stop

B Attachment screw plus washer, M12 x 40 quality 12.9 (2 pcs)
C Fixed mechanical stop
D Mechanical stop pin axis 1

Continued
Required equipment

Movable mechanical stop set, axis 1 3HAC025204-003 Includes:
(+15°/-7.5°) • one stop (+15°/ -7.5°),
3HAC025366-001
• one stop (+7.5°/ -15°),
3HAC025367-001
• attachment screws and
washers
• document for movable
mech.stop, 3HAC025204-
002
Standard toolkit -
Technical reference manual - System - Article number is specified in
parameters section References on page 10.
Installation, mechanical stops axis 1

Use this procedure to fit the additional mechanical stops to axis 1 of the robot. An
assembly drawing is also enclosed with the product.
Action Note
1
DANGER
Turn off all:

2 Fit the additional mechanical stop to the Tightening torque: 120 Nm.
frame according to the figure Mechanical
stops, axis 1 on page 84.
3 Adjust the software working range limitations The system parameters that must be
(system parameter configuration) to corres- changed (Upper joint bound and Lower
pond to the mechanical limitations. joint bound) are described in Technical
reference manual - System parameters.
4
WARNING
If the mechanical stop pin is deformed after

a hard collision, it must be replaced!
Deformed movable stops and/or additional
stops as well as deformed attachment
screws must also be replaced after a hard
collision.

2.6.1 Start of robot in cold environments
2.6 Robot in cold environments
2.6.1 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.

2.7.1 Robot cabling and connection points
2.7 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 robot 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 87.
Customer cables (option) Handles communication with equipment fitted on the robot
by the customer, low voltage signals and high voltage power
supply + protective ground.
See the product manual for the controller, see document
number in References on page 10.
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet
to the robot motors.
Robot cable, signals Transfers resolver data from XS2 R1.SMB
and power supply to the serial
measurement board.
Robot cable, power
Cable Art. no.

Robot cable, power: 7 m 3HAC026787-001

Continued
Cable Art. no.

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.
xx1600001956

2.7.2 Customer connectors on the manipulator
Introduction
The customer cables are routed internally with the manipulator cable harness. For
more information and specifications for the connections. See section Customer
connections in the Product Specification.
Location of customer connectors on manipulator

Customer connectors, base
xx2100001979
Pos Name Description

A FE Grounding point
B R1.CP/CS Customer power/signal
C R1.ETHERNET Bus communication Ethernet IP
D R1.PROC1 Process connector on the manipulator base.

Continued
Customer connectors, wrist
xx2100001980
Pos Name Description

A R1.CPS Customer power/signal connector
B R2.CAIR Customer air
C R1.ETHERNET Bus communication Ethernet IP
D FE Grounding point

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
460.
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 17 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 460 is connected to power, always make sure that the IRB 460 is
connected to protective earth and a residual current device (RCD) before starting
any maintenance work.
• Robot cabling and connection points on page 87.

3 Maintenance
3.2.1 Specification of maintenance intervals
3.2 Maintenance schedule and expected component life
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 460:
• 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.
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 table below.
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 97
Instructions for how to perform the different maintenance activities are found in
sections:
• Inspection activities on page 98
• Replacement/changing activities on page 117
• Cleaning activities on page 132
Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals.
Maintenance activity Equipment Interval
Cleaning Robot -
Inspection Axis-1 gearbox, oil level Every:
• 6 months
Inspection Axes-2 and -3 gearboxes, oil Every:
level • 6 months
Inspection Axis-6 gearbox, oil level Every:
• 6 months
Inspection Robot harness Every:
• 12 months i
Inspection Information labels Every:
• 12 months
Inspection Mechanical stop, axis 1 Every:
• 12 months
Mechanical stop, axis 3 (only Every:
applicable for IRB 760 - • 12 months
445/3.2)
Inspection Dampers Every:
• 12 months
Changing Axis-1 gear oil First change when DTC ii reads:
• 6,000 hours
Second change when DTC ii reads:
• 20,000 hours
Following changes:
• Every 20,000 hours

3 Maintenance
Continued

Changing Axis 2 gear oil First change when DTC ii reads:
• 6,000 hours
• 20,000 hours
Following changes:
• 6,000 hours
• 20,000 hours
Following changes:
• 6,000 hours
• 20,000 hours
Following changes:
Overhaul Robot 30,000 hours
Replacement Battery pack, measurement 36 months or battery low alert iii
system of type RMU101 or
RMU102 (3-pole battery con-
tact)
Replacement Battery pack, measurement Battery low alert iv
system with 2-pole battery
contact, e.g. DSQC633A
i Replace when damage or cracks are detected or life limit is approaching as specified in section
Expected component life on page 97.
ii DTC = Duty Time Counter. Shows the operational time of the robot.
iii 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.
iv The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the
robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime
can be extended with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.
Activities and intervals, optional equipment

The table below specifies the required maintenance activities and intervals for
common optional equipment. The maintenance of other external equipment for the
robot is detailed in separate documentation.
Inspection Signal lamp Every:
12 months

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
Component Expected life Note

Cable harness 30,000 hours i Optional upper arm har-
nesses not included.
Gearboxes ii 30,000 hours
i Severe chemical or thermal environments, or similar environments, can result in shortened life
expectancy.
ii Depending on application, the lifetime can vary. The Service Information System (SIS) that is
integrated in the robot software can be used as guidance when planning gearbox service for the
individual robot. This applies to gearboxes on axes 1, 2, 3 and 6. In some 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 the gearboxes. Contact the local ABB Robotics Service team
for more information.
The SIS for an M2004 system is described in the Operating manual - Service Information System.

3 Maintenance
3.3.1 Inspecting the oil level in axis-1 gearbox
3.3 Inspection activities
Location of gearbox
The axis-1 gearbox is located between the frame and base. See oil plugs in the
following figure.
xx1000001294
A Oil plug, inspection

B Oil plug, filing
Required equipment

Lubricating oil See Type and
amount of oil in Note
gearboxes on
page 117. Do not mix with other oils!
Standard toolkit - Content is defined in section

Standard tools on page 391.
Other tools and procedures may These procedures include refer-
be required. See references to ences to the tools required.

3 Maintenance
Continued
Inspecting the oil level in axis-1 gearbox

Use this procedure to inspect the oil level in the axis-1 gearbox.
Action Note
1
WARNING
Handling gearbox oil involves several safety risks,

see Gearbox lubricants (oil or grease) on page 32.
2
DANGER
Turn off all:

to the robot, before entering the safeguarded
space.
3 Make sure that the oil temperature is +25°C ±10°C. This is a precaution to reduce the
temperature dependency of the
measurement.
4 Open the oil plug, inspection. Shown in figure Location of gear-
box on page 98.
5 Measure the oil level. A
Required oil level: max. 5 mm below the oil plug
hole.
C
xx1400002785
A Oil plug hole

B Required oil level
C Gearbox oil
6 Adjust the oil level, if required. Where to find type of oil and total
amount is detailed in Type of lub-
rication in gearboxes on page 117.
Further information about how to
fill with oil is found in section
Changing oil, axis-1 gearbox on
page 118.
7 Refit the oil plug. Tightening torque:25 Nm

3 Maintenance
3.3.2 Inspecting, oil level gearbox axes 2 - 3
Location of gearbox, axes 2-3

The gearboxes axes 2-3 are located in the lower arm rotational center, underneath
the motor attachment.
xx1000001295
A Gearbox, axis 2
B Oil plug, filling

3 Maintenance
Continued
xx1000001297
A Gearbox, axis 3
B Oil plug, filling
Required equipment
Equipment etc. Art.no. Note

Lubricating oil See Type and
amount of oil in Note
gearboxes on

step instructions below
Inspecting, oil level gearbox 2 - 3

Use this procedure to inspect the oil level in gearbox axes 2 - 3.
Action Note
1
WARNING


3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

space.
3 Open oil plug, filling See Location of gearbox, axes 2-3

on page 100.
4 Measure oil level at the oil plug, filling.
Required oil level: max. 5 mm below oil plug hole.
5 Add oil if required. Art.no. is specified in Required
equipment on page 101.
Filling of oil is detailed further in
section Changing oil, gearbox axes
2 and 3 on page 122.
6 Refit oil plug, filling. Tightening torque: 25 Nm.

3 Maintenance
3.3.3 Inspecting, oil level gearbox axis 6
Location of gearbox
The axis 6 gearbox is located in the tilthouse unit as shown in this figure.
xx1000001301
A Gearbox, axis 6
B Oil plug, filling
Required equipment

Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150

3 Maintenance
Continued
Inspection, oil level axis-6 gearbox

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

2
DANGER
Turn off all:

to the robot, before entering the safeguarded space.
3 Open oil plug, filling. Shown in figure Location of gear-

box on page 103.
4 Required oil level: 23 mm ± 2 mm below the motor
mounting surface.
5 Add oil if required. Art. no. is specified in Required
Further information about how to
fill the oil may be found in the
section Changing oil, gearbox axis
6 on page 126.
6 Refit oil plug, filling. Tightening torque: 24 Nm

3 Maintenance
3.3.4 Inspecting, cable harness
Location of cable harness, axes 1-6

The axes-1-6 cable harness is shown below.
xx1000001373
A Cable harness robot, axes 1-6

B Connectors at base
C Motor cables
D Cable guide, axis 2
E Metal clamps
Required equipment
Visual inspection, no tools are needed.

3 Maintenance
Continued
Inspecting cable harness, axes 1-6

Use this procedure to inspect cable harness of axes 1-6.
Action Note
1
DANGER
Turn off all:

space.
2 Make an overall inspection of the cable har-

ness in order to detect wear and damage.
3 Check the connectors at the base. Shown in figure Location of cable har-
ness, axes 1-6 on page 105
4 Check the motor cables. Shown in figure Location of cable har-
ness, axes 1-6 on page 105.
5 Check the cable guide axis 2. Shown in figure Location of cable har-
Replace if damaged. ness, axes 1-6 on page 105.
6 Check the metal clamps on the lower arm. Shown in figure Location of cable har-
ness, axes 1-6 on page 105
7 Check the metal clamps holding the cable
harness inside the upper arm, as shown in
figure to the right.
xx0500002498
A: Metal clamp inside upper arm

8 Check the metal clamp holding the motor cable Shown in figure Location of cable har-
on axis 6. ness, axes 1-6 on page 105.
9 Replace the cable harness if wear or damage Detailed in section:
is detected! Replacing cable harness, lower end
(axes 1-3) on page 144.
Replacing the cable harness, upper end
(incl. axis 6) on page 154.

3 Maintenance
3.3.5 Inspecting the information labels
Location of labels
These figures show the location of the information labels to be inspected. The
symbols are described in section Safety symbols on manipulator labels on page 21.
H H
B B
A
K
N
C
A
D
F B G
M
K
L
K A B
J
A
xx1000001292
A Warning label "Heat" (located on motor cover), 3HAC4431-1 (4 pcs)

B Warning label, symbol of flash (located on motor cover), 3HAC1589-1 (4 pcs)
C Combined warning label "Moving robot", "Shut off with handle" and "Before
dismantling see product manual", 3HAC17804-1

3 Maintenance
Continued
D Combined warning label "Brake release", "Brake release buttons" and "Moving
robot", 3HAC054583-001
E Instruction label for lifting of robot, 3HAC039135-001
F Warning label "Tip risk when loosening bolts", 3HAC9191-1
G Information label at base, specifying which oil is filled in gearboxes, 3HAC032906-
001
H ABB Logotype, 3HAC17765-2 (2 pcs)
J UL label, 3HAC2763-1
K Information label near each gearbox, specifying which oil is used in gearboxes,
3HAC032726-001 (4 pcs)
L Label serial number
M Label calibration
N Label, battery
P Label, stock robots
Required tools and equipment

Visual inspection, no tools are required.
Inspecting, labels
Action Note
1
DANGER
Turn off all:

2 Inspect the labels, located as shown in the figures.

3 Replace any missing or damaged labels. Article numbers for the labels and
plate set is specified in Spare
parts on page 397.

3 Maintenance
3.3.6 Inspecting the axis-1 mechanical stop pin
WARNING
Mechanical stop pin can not be fitted onto robot if option 810-1 Electronic Position
Switch is used.
WARNING
Mechanical stop pin can not be fitted onto robot if option 561-1 Extended work
range axis 1 is used.
Location of mechanical stop pin

The axis-1 mechanical stop is located as shown in the figure.
xx1000001302
A Mechanical stop pin, axis 1
Required equipment
Visual inspection, no tools are required.
Inspecting, mechanical stop pin

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

space.
3 Maintenance
Continued
Action Note
2 Inspect the axis-1 mechanical stop pin.
If the mechanical stop pin is bent or damaged, it
must be replaced.
Note
The expected life of gearboxes can be reduced

after collision with the mechanical stop.

3 Maintenance
3.3.7 Inspecting the additional mechanical stops
Location of mechanical stops

This figure shows the location of the additional mechanical stop on axis 1.
xx0600002938
A Additional stop, axis 1

B Attachment screws and washers (2 pcs)
C Fixed stop
D Mechanical stop pin, axis 1
Required equipment
Equipment etc. Article number Note

Mechanical stop See Spare parts on
page 397.
tools on page 391.

3 Maintenance
Continued
Inspecting, mechanical stops

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

to the robot, before entering the robot working area.
2 Make sure no additional stops are damaged. Shown in figure Location of

mechanical stops on page 111.
3 Make sure the stops are properly attached.
Correct tightening torque, additional mechanical
stops:
• Axis 1 = 120 Nm.
4 If any damage is detected, the mechanical stops must Article number is specified in
be replaced. Required equipment on page 111.
Correct attachment screws:
• Axis 1: M12 x 40, quality 12.9.

3 Maintenance
3.3.8 Inspection, dampers
Location of dampers
This figure shows the location of dampers.
xx1000001345
A Damper, lower arm, upper (2 pcs)

B Damper, lower arm, lower (2 pcs)
C Damper, axis 2 (2 pcs)
- Damper, axis 3 (2 pcs). Not visible in this view.
Required equipment
Equipment Art.no. Note

Damper lower arm, upper See Spare parts on To be replaced if damaged.
page 397.
Damper lower arm, lower See Spare parts on To be replaced if damaged.
page 397.
Damper axis 2, 3 See Inspection, To be replaced if damaged.
dampers on page 113.

3 Maintenance
Continued
Inspecting, dampers
Use this procedure to inspect the dampers.
Action Note
1
DANGER
Turn off all:

space.
2 Check all dampers for damage, cracks or existing Shown in figure Location of
impressions larger than 1 mm. dampers on page 113.
3 Check attachment screws for deformation.
4 If any damage is detected, the damper must be Art.no. is specified in Required
replaced with a new one. equipment on page 113.

3 Maintenance
3.3.9 Inspecting the signal lamp (option)
Location of signal lamp

The signal lamp is located as shown in this figure.
C
B
F
A
x-x
xx1000001288
A Signal lamp bracket

B Attachment screws, M8x12 and bracket (2 pcs)
C Cable straps (2 pcs)
D Cable gland cover
E Motor adapter including gasket
F Attachment screw, M6x40 (1 pc)
Required tools and equipment

Signal lamp kit See Spare parts on To be replaced if damage is detected.
page 397.
Standard toolkit - Content is defined in section Stand-
Inspecting, signal lamp

Use this procedure to inspect the function of the signal lamp.
Action Note
1 Inspect that signal lamp is lit when motors are put in
operation ("MOTORS ON").

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

3 If the lamp is not lit, trace the fault by: Article number is specified in Re-
• inspecting whether the signal lamp is broken. quired tools and equipment on
If so, replace it. page 115.
• inspecting cable connections.
• measuring the voltage in the connectors of
motor axis 6 (=24V).
• inspecting the cabling. Replace the cabling if
a fault is detected.

3 Maintenance
3.4.1 Type of lubrication in gearboxes
3.4 Replacement/changing activities
3.4.1 Type of lubrication in gearboxes
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.
Location of gearboxes
The figure shows the location of the gearboxes.
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

3 Maintenance
3.4.2 Changing oil, axis-1 gearbox
Location of oil plugs

The axis-1 gearbox is located between the frame and base. See oil plugs in the
following figure.
falseThe oil is drained through a hose, which is located at the rear of the robot
base.
xx1000001294
A Oil plug, inspection

B Oil plug, filling

3 Maintenance
Continued
xx1000001346
A Oil plug, draining
Required equipment
Equipment, etc. Art. no. Amount Note

Lubricating oil See Type and See Type
amount of oil in and Note
gearboxes on amount of
page 117. oil in gear- Do not mix with other oils!
boxes on
page 117.
Oil collecting vessel - Capacity: 8,000 ml.
Oil exchange equip- 3HAC021745-001 Content is defined in section
ment Special tools on page 392.

3 Maintenance
Continued
Draining oil, axis-1 gearbox

Use this procedure to drain oil in gearbox axis 1.
Action Note
1
DANGER
Turn off all:

2
WARNING

3 Remove oil plug, filling, in order to drain oil quicker! Shown in Location of oil plugs on
page 118.
4 Remove oil plug, draining, and drain gearbox using Shown in Location of oil plugs on
a hose with a nipple and an oil collecting vessel. page 118.
Vessel capacity is specified in
Required equipment on page 119.
Note
Draining is time-consuming.
Elapsed time depends on the
temperature of the oil.
5 Refit oil plugs. Tightening torque: 25 Nm.
Filling oil, axis-1 gearbox

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

2
WARNING

3 Open the oil plug, filling. Shown in figure Location of oil

plugs on page 118.

3 Maintenance
Continued
Action Note
4 Refill the gearbox with clean lubricating oil. Where to find type of oil and
The correct oil level is detailed in section Inspecting total amount is detailed in Type
the oil level in axis-1 gearbox on page 98. and amount of oil in gearboxes
on page 117.
5 Refit the oil plug, filling. Tightening torque: 25 Nm.

3 Maintenance
3.4.3 Changing oil, gearbox axes 2 and 3

Gearboxes, axes 2 and 3, are located in lower arm rotational center, underneath
motor attachment.
The figure shows the position of gearbox, axis 2.
xx1000001348
A Ventilation hole plug, gearbox axis 2

B Oil plug, filling
C Oil plug, draining

3 Maintenance
Continued
The figure shows position of gearbox, axis 3.
xx1000001351
A Ventilation hole plug, gearbox axis 3

B Oil plug, filling
C Oil plug, draining
Required equipment
Equipment etc. Art. no. Amount Note

Lubricating oil See Type and 3,200 ml in
amount of oil in each gearbox Note
gearboxes on
Oil collecting vessel Capacity: 4,000 ml

Oil exchange equip- 3HAC021745-001 Content is defined in section
ment Special tools on page 392.

3 Maintenance
Continued
Draining, axes 2 and 3

Use this procedure to drain oil in gearbox axes 2 and 3.
When using oil change equipment, follow the instructions enclosed with kit.
Action Note
1
DANGER
Turn off all:

space.
2
WARNING
Handling gearbox oil involves several safety

risks, see Gearbox lubricants (oil or grease)
on page 32.
3 Remove the ventilation hole plug. Shown in Location of oil plugs on

page 122.
4 Remove the oil plug, draining, and drain gear- Shown in Location of oil plugs on
box using a hose with a nipple and an oil col- page 122.
lecting vessel. Vessel capacity is specified in Re-
quired equipment on page 123.
Draining is time-consuming.
Elapsed time varies depending on the
temperature of the oil.
5 Refit the oil plug, draining. Tightening torque: 25 Nm.
Filling, axes 2 and 3

Use this procedure to fill gearboxes of axes 2 and 3 with oil.
Action Note
1
DANGER
Turn off all:

space.
2
WARNING
Handling gearbox oil involves several safety

risks, see Gearbox lubricants (oil or grease)
on page 32.

3 Maintenance
Continued
Action Note
3 Remove the oil plug, filling. (Ventilation hole Shown in Location of oil plugs on
plug should also be removed.) page 122.
Tightening torque: 24 Nm.
4 Refill gearbox with lubricating oil. Art.no. and total amount are specified
The amount of oil to be filled depends on the in Required equipment on page 123.
amount that was previously drained.
5 Refit oil plug,filling and ventilation hole plug. Shown in Location of oil plugs on
page 122.

3 Maintenance
3.4.4 Changing oil, gearbox axis 6

Gearbox axis 6 is located in the center of the tilt house unit.
xx1000001353
A Oil plug, draining

B Oil plug, filling
Required equipment
Equipment, etc. Art. no. Amount Note

Lubrication oil 3HAC032140-001 300 ml Kyodo Yushi TMO 150
Do not mix with other oil types!
Oil exchange equipment 3HAC021745-001
Oil collecting vessel Vessel capacity: 400 ml.
Draining, oil
Use this procedure to drain oil from gearbox axis 6.
Action Note
1 Put tilt house in a suitable position.

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

space.
3 Drain oil from gearbox into a vessel by removing Shown in figure Location of oil plugs
oil plug, draining. on page 126.
Also remove oil plug, filling. Vessel capacity is specified in Re-
quired equipment on page 126.
4 Refit oil plugs, draining and filling. Tightening torque: 24 Nm.
Filling, oil
Use this procedure to fill gearbox axis 6 with oil.
Action Note
1
DANGER
Turn off all:

space.
2 Remove the oil plug, filling. Shown in figure Location of oil

plugs on page 126.
3 Refill the gearbox with lubricating oil. Art. no. and the total amount are
Amount of oil to be refilled depends on the specified in Required equipment
amount that was previously drained. Correct oil on page 126.
level is detailed in section Inspection, oil level
axis-6 gearbox on page 104.
4 Refit the oil plug. Tightening torque: 24 Nm.

3 Maintenance
3.4.5 Replacing the 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 a 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 a SMB board with 2-pole battery contact (DSQC), the typical lifetime of a new
battery is 36 months if the robot is powered off 2 days/week or 18 months if the
robot is powered off 16 h/day. The lifetime can be extended for longer production
breaks with a battery shutdown service routine. See Operating manual - IRC5
with FlexPendant for instructions.
WARNING
See Hazards related to batteries on page 33.
Location of SMB battery

The SMB battery (SMB = serial measurement board) is located on the left hand
side of the frame as shown in the figure.
Battery pack with a 2-pole battery contact (DSQC)
xx1000001360
A SMB battery pack

B SMB battery cover

3 Maintenance
Continued
Battery pack with a 3-pole battery contact (RMU)

C
A
B
xx1300001116
A Battery pack RMU

B Battery holder
C Battery cable
Required equipment
Note
There are two variants of SMB units and batteries. One with 2-pole battery contact
(DSQC) and one with 3-pole battery contact (RMU). 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 exchange battery contacts!
Equipment, etc. Spare part no. Note

Battery unit For spare part no. Battery includes protection circuits. Only re-
see: place with a specified spare part or an ABB-
• Spare parts approved equivalent.
on page 397
Standard toolkit - Content is defined in section Standard tools
on page 391.
Circuit diagram - See chapter Circuit diagrams on page 399.
Removing, 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
updating of the revolution counter.

3 Maintenance
Continued
Action Note
2
DANGER
Turn off all:

space.
3
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the

unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 47
4 Remove the SMB battery cover by unscrewing the Shown in figure Location of SMB
attachment screws. battery on page 128.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
5 Pull out the battery and disconnect the battery Shown in figure Location of SMB
cable. battery on page 128.
6 Remove the SMB battery. Shown in figure Location of SMB
Battery includes protection circuits. Only replace battery on page 128.
with a specified spare part or with an ABB- ap-
proved equivalent.
Refitting, battery
Use this procedure to refit the SMB battery.
Action Note
1
DANGER
Turn off all:

space.
2

unit please read the safety information in the sec-
tion The unit is sensitive to ESD on page 47

3 Maintenance
Continued
Action Note
3 Reconnect the battery cable and install the battery Art. no. is specified in Required
pack into the SMB/battery recess. equipment on page 129.
Shown in figure Location of SMB
Note battery on page 128.
C
RMU batteries are installed together with a battery
holder to be properly secured inside the recess.
See figure.
A
B
xx1300001116
A Battery pack RMU

B Battery holder
C Battery cable
4 Secure the SMB battery cover with its attachment Shown in figure Location of SMB
screws. battery on page 128.
5 Update the revolution counters. Detailed in chapter Calibration -
section Updating revolution coun-
ters on IRC5 robots on page 359.
6
DANGER
Make sure all safety requirements are met when

performing the first test run.

3 Maintenance
3.5.1 Cleaning the IRB 460
3.5 Cleaning activities
DANGER
Turn off all:

General
To secure high uptime it is important that the IRB 460 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 460.
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 98.
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.
Cleaning with water and steam

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

• Minimum distance from nozzle to encapsulation: 0.4 meters
• Maximum flow: 20 liters/min I
I Typical tap water pressure and flow
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.
1 See Cleaning methods on page 133 for exceptions.

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

This chapter describes repair activities for the IRB 460. 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 460, 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 17 before commencing any
service work.
Note
If the IRB 460 is connected to power, always make sure that the IRB 460 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.
Required equipment

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

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

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

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

Grease 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

Rotating sealings
The procedure below describes 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.
• 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.
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 139.
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

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
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, preferably with a brush.
4 Tighten the screws evenly when fastening the flange joint.
O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.

4 Repair
Continued
Action Note
3 Check the o-ring grooves.
The grooves must be geometrically correct and
should be free of pores and contamination.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Check that the o-ring is not squashed outside
the o-ring groove.

4 Repair
4.2.4 Cut the paint or surface on the robot before replacing parts
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.
Required equipment
Equipment Spare parts Note

Cleaning agent Ethanol
Knife
Lint free cloth
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.
xx0900000121
2 Carefully grind the paint edge that is left on

the structure to a smooth surface.

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 Replacing cable harness, lower end (axes 1-3)
4.3 Complete robot
Overview
The cable harness 1-6 is undivided.
How to replace the cable harness is described in two steps - lower end (axes 1-3)
and upper end (axis 6). This procedure describes how to replace the lower end of
the cable harness. How to replace the upper end can be found in section Replacing
the cable harness, upper end (incl. axis 6) on page 154.

4 Repair
Continued
Location of cable harness - lower end (axes 1-3)

The cable harness, lower end (axes 1-3) is located throughout the base, frame and
lower arm as shown in the figure.
xx1100000153

4 Repair
Continued
xx1100000154
A Rear cover plate

B Cable guide, axis 2
C Metal clamp
D SMB cover
R2.MP6, R2.FB6 Connectors to the axis 6 motor
Required equipment
Equipment, etc. Art.no. Note

Cable harness 1-6 For spare part no. see:
• Spare parts on
page 397
Gasket 3HAC3438-1 Motor, axes 1-3
Replace if damaged.
Standard toolkit - The content is defined in the sec-
tion Standard tools on page 391.

4 Repair
Continued

Other tools and proced- - These procedures include refer-
ures may be required. See ences to the tools required.
references to these proced-
ures in the step-by-step in-
structions below.
Circuit diagram - See Circuit diagrams on page 399.
Removing the cable harness - lower end (axes 1-3)

Use this procedure to remove the cable harness, lower end (axes 1-3).
Action Note
1 Move the robot to the calibration position. This is done in order to facilitate updat-
ing of the revolution counter.
2
DANGER
Turn off all:

area.
3 Remove the rear cover plate from the robot by

removing its attachment screws.
xx1100000155

4 Repair
Continued
Action Note
4 Disconnect the earth cable.
xx1100000156
5 Disconnect the connectors R1.MP and R1.SMB. See the figure Location of cable har-
ness - lower end (axes 1-3) on
page 145.
6 Unscrew the screws of the cable guide axis 2
inside the lower arm and loosen the cable
guide.
xx1100000157
7 Unscrew the nuts (outside the lower arm) that

secure the metal clamp that hold the cable
harness inside the lower arm.
8 Unscrew the screws of the motor covers for
axes 1, 2 and 3 and lift away the covers. This
is done in order to reach the motor connectors.
9 Disconnect all connectors at motors for axes See sections:
1, 2 and 3. • Replacing motor, axis 1 on
page 293
• Replacing motors, axes 2 and 3
on page 300

4 Repair
Continued
Action Note
10 Open the SMB cover carefully. See the figure Location of cable har-
ness - lower end (axes 1-3) on
page 145.
11 Disconnect connector R1.G on the battery
cable between the battery and the SMB unit.
Note
This causes a necessary updating of the revolu-

tion counter after refitting!
12 Disconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB6 from the SMB unit.
13 Disconnect X8, X9 and X10 from the brake re-
lease unit.
14 Remove the SMB cover and put somewhere
safe.
15 Unscrew the screws for the cable gland SMB
from inside the SMB recess and lift the cable
gland out.
Perform this removal with care, in order not to
damage any of the components inside the SMB
recess.
xx1000001330

4 Repair
Continued
Action Note
16 Gently pull the cable harness out from the base
through the cable guide, axis 1 and frame.
xx1000001331
17 Continue removing the cable harness in the See section Replacing the cable har-
upper arm. ness, upper end (incl. axis 6) on
page 154.
Refitting, cable harness - lower end (axes 1-3)

Use this procedure to refit the cable harness, lower end (axes 1-3).
Action Note
1 Push the cable harness and connectors down
through the cable guide axis 1 in the center of
the frame.
CAUTION
Make sure the cables are not twisted with each

other or with customer harness (if any)!
xx1000001331

4 Repair
Continued
Action Note
2 Pull out the cables and connectors of the SMB
unit through the frame and refit the cable gland
with its attachment screws from inside the SMB
recess.
Perform this refitting with care, in order not to
damage any of the components inside the SMB
recess.
xx1000001330
3 Reconnect connectors R1.MP and R1.SMB at Tightening torque for R1.SMB: 10 Nm.
the robot base. Attachment points are shown in the
figure Location of cable harness -
lower end (axes 1-3) on page 145.
4 Reconnect the earth cable.
xx1100000156

4 Repair
Continued
Action Note
5 Refit the rear cover plate to the robot base with
its attachment screws.
xx1100000155
6 Reconnect all connectors at motors axes 1, 2 See sections:

and 3 and refit the motor covers. • Replacing motor, axis 1 on
page 293
• Replacing motors, axes 2 and
3 on page 300
7 Reconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB6 of the SMB unit.
Reconnect X8, X9 and X10 to the brake release
unit.
Reconnect R1.G.
8 Secure the SMB cover with its attachment
screws.
If cabling is used for 7th axis (option), refit the
connector R2.FB7 to the SMB cover and tighten
with 6 Nm.
9
WARNING
Before continuing any service work, please

observe the safety information in section The
brake release buttons may be jammed after
service work on page 143.
10 Push the cable harness up through the lower

arm.
11 Fasten the metal clamp that hold the cable
harness in the lower arm with the nuts.

4 Repair
Continued
Action Note
12 Refit the cable guide, axis 2.
xx1100000157
13 Continue refitting the cable harness in the upper See section Replacing the cable har-
arm. ness, upper end (incl. axis 6) on
page 154.
14 Update the revolution counter! See section Updating revolution
counters on IRC5 robots on page 359.
15
DANGER


4 Repair
4.3.2 Replacing the cable harness, upper end (incl. axis 6)
Overview
Replacement of the cable harness is detailed in two steps - lower end (axes 1-3)
and upper end. The procedure below details replacement of the cable harness in
the upper end (incl. axis 6). The procedure for replacing the lower end (axis 1-3)
is detailed in section Replacing cable harness, lower end (axes 1-3) on page 144.
Location of cable harness, upper end

The upper end of the cable harness is located as shown in the figure.
xx1100000158

4 Repair
Continued
The motor axis 6 is located as shown in the figure below.
R2.MP6
R2.FB6
xx1100000159
• A: Metal clamps with nuts (upper arm)

• B: Metal clamp (tilthouse)
• R2.MP6, R2.FB6 = Connectors to the axis 6 motor
Required equipment
Equipment, etc Art.no. Note

Cable harness, 1-6 For spare part no. see:
• Spare parts on
page 397
Gasket - Motor, axis 6

4 Repair
Continued

Other tools and procedures may These procedures include
be required. See references to references to the tools re-
these procedures in the step-by- quired.
Circuit diagram See chapter Circuit dia-
grams on page 399.
Removing cable harness, upper end (incl. axis 6)

Use this procedure to remove the cable harness, upper arm (incl. axis 6).
Action Note
1 Move the robot to the calibration position. This is done in order to facilitate updating
of the revolution counter.
2
DANGER
Turn off all:

to the robot, before entering the robot
working area.
3 If the complete cable harness is being re- Detailed in section Replacing cable har-
placed, start removal by removing the cable ness, lower end (axes 1-3) on page 144.
harness, lower end.
4 Remove the axis 6 motor cover by removing
its attachment screws, in order to reach the
connectors.
xx1000001106

4 Repair
Continued
Action Note
Remove the cable gland cover at the cable
exit by unscrewing its attachment screw on
the inside.
Note
Make sure the gasket is not damaged!
xx0600002694
• A: Screw securing the cable gland

5 Disconnect connectors at axis 6 motor.
6 Remove the metal clamp that holds the
cable at the tilt house, by removing its nuts.
xx1000001336
7 Carefully pull the cable harness out of motor

axis 6.

4 Repair
Continued
Action Note
8 Remove the nuts (on the outside of the up-
per arm) that secure the cable harness
metal clamps inside the upper arm (2 + 2
pcs).
xx1000001338
9 Carefully pull out the cable harness from

the upper and lower arm.
Refitting cable harness, upper end

Use this procedure to refit the cable harness, upper end.
Action Note
1 Start by fitting the cable harness, lower end Detailed in section Replacing cable har-
if it has been removed. ness, lower end (axes 1-3) on page 144
2 Push the cable harness through the upper
arm tube.

4 Repair
Continued
Action Note
3 Refit the cable harness inside the upper arm
by refitting the cable clamps with the nuts
(2 + 2 pcs) from the outside of the upper
arm.
xx1000001338
4 Refit the metal clamp at the tilthouse with

its nuts.
xx1000001336
5 Push the axis 6 motor cables carefully

through the cable gland.
Note
Do not twist the cables!
6 Reconnect all connectors in motor axis 6.

7 Check the gasket. If damaged, replace it.

4 Repair
Continued
Action Note
8 Refit the cable gland with its attachment
screw.
xx0600002694
• A: Screw holding the cable gland

Replace if damaged.
9 Refit the cover, motor axis 6 with its attach-
ment screws and washers. Make sure the
cabling is placed correctly when refitting
the cover and does not get jammed.
Note
Make sure the cover is tightly sealed!
xx1000001106
10 Update the revolution counter! Detailed in section Updating revolution

counters on IRC5 robots on page 359.
11
DANGER
Make sure all safety requirements are met

when performing the first test run.

4 Repair
4.3.3 Replacing customer cable harness (optional)
Overview
Three types of customer cable harness are available for IRB 460:
• Cable harness with Parallel/DeviceNet/Profibus and air hoses
• Cable harness with Parallel and air hoses
• Cable harness with Parallel/Ethernet and air hoses
Location of customer cable harness

The customer cable harness is located as shown in the figure.
xx2100002528
Required equipment

Cable harness, Customer 3HAC040447-001
CP/CS/CBUS
CP/CS
Ethernet/CP/CS
Standard toolkit - The content is defined in the sec-
tion Standard tools on page 391.

4 Repair
Continued

Other tools and proced- - These procedures include refer-
ures in the step-by-step in-
structions below.
Circuit diagram - See Circuit diagrams on page 399.
Removing the customer cable harness

Use this procedure to remove the customer cable harness.
Action Note
1 Move the robot to the calibration position. This is done in order to facilitate updat-
ing of the revolution counter.
2
DANGER
Turn off all:

area.
3 Remove the rear cover plate from the robot by

removing its attachment screws.
xx2100002529

4 Repair
Continued
Action Note
4 Disconnect the connectors on the base.
For cable harness with Parallel + Devi-
ceNet/Profibus + air hoses
• R1.CP/CS (A)
• R1.PROC1 (B)
xx2100002530
For cable harness with Parallel + air hoses

• R1.CP/CS (A)
• R1.PROC1 (B)
xx2100002530
For cable harness with Parallel + Ethernet +

air hoses
• FE (A)
• R1.CP/CS (B)
• R1.PROC1 (C)
• R1.ETHERNET (D)
xx2100002531

4 Repair
Continued
Action Note
5 Disconnect the connectors on the tilthouse unit.
• R2.CBUS (A)
• R2.CPS (B)
• R2.CAIR (C)
xx2100002532

• R2.CPS (A)
• R2.CAIR (B)
xx2100002533

air hoses
• R2.CPS (A)
• R2.CAIR (B)
• R2.ETHERNET (C)
• FE (D)
xx2100002534
6 Remove the metal clamp that holds the cable

at the tilt house, by removing its nuts.
xx2100002535

4 Repair
Continued
Action Note
7 Remove the nuts (on the outside of the upper
arm) that secure the metal clamps that hold the
cable harness inside the upper arm (2 pcs + 2
pcs).
xx2100002536
8 Remove the nuts (on the outside of the lower

arm) that secure the metal clamp that holds the
cable harness inside the lower arm (2 pcs).
xx2100002537
9 Remove the nuts that secure the metal clamp

that holds the cable harness in the fame (2
pcs).
xx2100002538
10 Remove the cable protection tube.
xx2100002539
11 Wrap the connectors with masking tape for

protection.
12 Gently pull the cable harness out from the up-
per arm and lower arm.
13 Gently pull the cable harness out from the base
through the cable guide, axis 1 and frame.

4 Repair
Continued
Refitting the customer cable harness

Use this procedure to refit the customer cable harness.
Action Note
1 Wrap the connectors with masking tape for
protection.
2 Push the cable harness down through the cable
guide axis 1 in the center of the frame.
CAUTION
Make sure the cables are not twisted with each

other or with other motor harness!
3 Fasten the metal clamp that holds the cable

harness in the frame with the nuts (2 pcs).
xx2100002538
4 Guide the cable harness up through the cable

guide, axis 2 and into the lower arm, and then
push the cable harness up through the upper
arm.
xx2100002540

harness in the lower arm with the nuts (2 pcs).
xx2100002537

4 Repair
Continued
Action Note
6 Fasten the metal clamps that hold the cable
harness in the upper arm with the nuts (2 pcs
+ 2 pcs).
xx2100002536

harness in the tilthouse unit with the nuts (2
pcs).
xx2100002535
8 Fix the cable protection tube around the cables

in the lower arm and upper arm.
xx2100002539

4 Repair
Continued
Action Note
9 Reconnect the connectors on the base.
• R1.CP/CS (A)
• R1.PROC1 (B)
xx2100002530

• R1.CP/CS (A)
• R1.PROC1 (B)
xx2100002530

air hoses
• FE (A)
• R1.CP/CS (B)
• R1.PROC1 (C)
• R1.ETHERNET (D)
xx2100002531

4 Repair
Continued
Action Note
10 Reconnect the connectors on the tilthouse unit.
• R2.CBUS (A)
• R2.CPS (B)
• R2.CAIR (C)
xx2100002532

• R2.CPS (A)
• R2.CAIR (B)
xx2100002533

air hoses
• R2.CPS (A)
• R2.CAIR (B)
• R2.ETHERNET (C)
• FE (D)
xx2100002534
11 Refit the rear cover plate to the robot base with Tightening torque: 6 Nm
xx2100002529
12
WARNING
Before continuing any service work, please

observe the safety information in section The
brake release buttons may be jammed after
service work on page 143.

4 Repair
Continued
Action Note
13
DANGER


4 Repair
4.3.4 Replacing the SMB unit
Location of SMB unit

The SMB unit (SMB = serial measurement board) is located on the left hand side
of the frame as shown in the figure.
SMB board DSQC 633A (with 2-pole contact)
xx1100000105
A Battery pack (2-pole battery contact)

B Cover
C BU button guard plate
D Push button guard
E Cover SMB
F SMB unit
G Brake release unit

4 Repair
Continued
SMB board RMU 101 (with 3-pole contact)
A B C
D
E
F G
xx1300001115
A Battery box
B Battery holder
C Battery pack, RMU lithium (3-pole battery contact)
D SMB cover
E Battery cover
F BU button guard plate
G Push button guard
H Serial measurement board, RMU 101
Required equipment
Note
There are different variants of SMB units and batteries. 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!

SMB unit For spare part number,
see: Spare parts on
page 397.

4 Repair
Continued

Battery pack For spare part number,
see: Spare parts on
page 397.
tools on page 391.
Circuit diagram - See chapter Circuit diagrams on
page 399.
Removing, SMB unit

Use this procedure to remove the SMB unit.
Action Note
1 Move the robot to the calibration position.
2
DANGER
Turn off all:

3
The unit is sensitive to ESD. Before handling the unit

read the safety information in section The unit is
sensitive to ESD on page 47.
4 Remove the SMB cover by unscrewing its attachment Shown in the figure Location of
screws. SMB unit on page 171.
CAUTION
Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.
5 Use caution and remove the connectors X8, X9 and

X10 from the brake release board, if need of more
space.
6 Remove the nuts and washers from the guide pins Shown in the figure Location of
that secure the board. SMB unit on page 171.
7 Use caution and disconnect the connectors from the Connectors R1.SMB1-3,
SMB unit when pulling the board out. R1.SMB4-6 and R2.SMB

4 Repair
Continued
Action Note
8 Disconnect the battery cable by pressing down the
upper lip of the R2.G connector to release the lock
while pulling the connector upwards.
xx1700000993
Refitting, SMB unit

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

area.
2

unit read the safety information in section The
unit is sensitive to ESD on page 47.
3 Connect the battery cable to the SMB unit. Shown in the figure Location of SMB
Make sure the lock on the battery cable connect- unit on page 171.
or R2.G snaps into place during refitting.
4 Connect all connectors to the SMB board: Art. no. is specified in Required
R1.SMB1-3, R1.SMB6 and R2.SMB equipment on page 172.
Shown in the figure Location of SMB
unit on page 171.
5 Fit the SMB unit onto the guide pins.
6 Secure the SMB unit to the pins with the nuts
and washers.
7 If disconnected, reconnect the 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
X9
are snapped down properly.
xx1700000978

4 Repair
Continued
Action Note
8 Secure the SMB cover with its attachment Shown in the figure Location of SMB
screws. unit on page 171.
If cabling is used for 7th axis (option), refit the
7th axis connector to the SMB cover and tighten
with 6 Nm.
9 Update the revolution counters. See Updating revolution counters on
IRC5 robots on page 359.
10
DANGER


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

The brake release unit is located together with the SMB unit on the left hand side
of the frame, right next to the gearbox, axis 2, as shown in figure below.
xx1100000105
A Battery pack (2-pole battery contact)

B Cover
C BU button guard plate
D Push button guard
E Cover SMB
F SMB unit
G Brake release unit

4 Repair
Continued
Required equipment

Brake release board 3HAC065020- DSQC1050
001
tools on page 391.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
Removing, brake release board

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

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 47.
3 Remove the push button guard from the SMB Shown in the figure Location of brake
cover. release board on page 176.
The guard must be removed to ensure
a correct refitting of the brake release
board.
4 Open the SMB cover by unscrewing the attach- Shown in the figure Location of brake
ment screws. release board on page 176.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
CAUTION
Clean cover from metal residues before

opening.
Metal residues can cause shortage on the
boards which can result in hazardous failures.
5 Take a picture or make notes of how the robot

cabling is positioned in regard to the brake
release board.
6 Remove the complete brake release board
(including brake release board and bracket)
from the SMB recess, by removing its two at-
tachment screws.

4 Repair
Continued
Action Note
7 Disconnect the connectors X8, X9 and X10
from the brake release board.
X8
X10
X9
xx1700000978
Location of the brake release unit is

shown in the figure Location of brake
release board on page 176.
8 Remove the brake release board from the
bracket by removing the four attachment
screws.
Refitting, brake release board

Use this procedure to refit the brake release board.
Action Note
1
The unit is sensitive to ESD. Before handling

the unit read the safety information in section
The unit is sensitive to ESD on page 47.
2 Connect the 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
3 Fasten the brake release board on the bracket Maximum tightening torque: 5 Nm.
with the attachment screws. Shown in the figure Location of brake
Make sure the board is positioned as straight release board on page 176.
as possible on the bracket! The push buttons
can otherwise get jammed when the SMB Art. no. is specified in Required equip-
cover is refitted. ment on page 177.
4 Refit the complete brake release board (includ-

ing brake release board and bracket) to the
SMB recess with the two attachment screws.
5 Verify that the robot cabling is positioned cor-
rectly, 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
6 Refit the SMB cover with its attachment Shown in the figure Location of brake
screws. release board on page 176.
7
WARNING
Before continuing any service work, follow the

safety procedure in The brake release buttons
may be jammed after service work on page 143.
8 Refit the push button guard to the SMB cover. Shown in the figure Location of brake
release board on page 176.
9 Press the push buttons 1 to 6, one at a time,
to make sure that the buttons are moving
freely and do not stay in a locked position.
10 If the battery has been disconnected the revolu- Detailed in the Calibration chapter -
tion counter must be updated. section Updating revolution counters
on IRC5 robots on page 359.
11
DANGER


4 Repair
4.3.6 Replacing the base, including axis 1 gearbox
Introduction
The term complete arm system used in this procedure is defined as the complete
robot excluding:
• base
• gearbox axis 1
Location of the base

The location of the base, including gearbox axis 1, is shown in the figure. It also
shows the complete arm system as defined above.
xx1100000246

4 Repair
Continued
Required equipment
Equipment, etc. Art. no. Note

Guide pins M12 x 130 3HAC022637-001 Used to guide the complete
arm system when refitting.
Always use the guide pins in
pairs!
Guide pins that are longer
than 140 mm will not be pos-
sible to remove because the
lack of space.
Roundsling 4 pcs.
Lifting capacity 1,000 kg
Adapter 3HAC040381-001
Lifting eye, M12 3HAC025333-005
Shackle - Lifting capacity: 1,000 kg.
Bits holder - Stahlwille 736/40 D10 (or
similar)
Used on the M12x140 screws.
Power supply - 24 VDC, max. 1.5 A
For releasing the brakes.
Crank - Used to turn the gear when
mating it to the frame.
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.
Circuit diagram - See chapter Circuit diagrams
on page 399.
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.

4 Repair
Continued
Action Note
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 364.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removing the complete arm system

Use this procedure to remove the complete arm system.
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 transport position. 40°
25°
m
xx1000001155
3
DANGER
Turn off all:

to the robot, before entering the robot work-
ing area.
4 Run an overhead crane to a position above

the robot.

4 Repair
Continued
Action Note
5 Remove the mechanical stop pin from the
frame.
xx1000001302
• A: Mechanical stop pin

6 Drain the axis 1 gearbox. See Changing oil, axis-1 gearbox on
page 118.
7 Loosen the cable connectors from the base See Replacing cable harness, lower end
and pull up the cabling from the base, (axes 1-3) on page 144.
through the hole in the center of the frame.
8 Remove the axis 1 motor. See Replacing motor, axis 1 on page 293.
9
CAUTION
The robot arm system weighs 750 kg.

accordingly!
10 Fit the roundslings as described in Fitting the

lifting accessories to the complete arm sys-
tem on page 185.
11 Stretch the roundslings so that they secure Adjust the length of each roundsling so
the weight of the arm system. that the lift is done completely level.
12 Unfasten the arm system from the base by
unscrewing the attachment screws.
Note
Use a bits holder with a thin head to remove

the screws. For example Stahlwille 736/40
D10 or similar. The space is cramp.
xx1100000247
13 Fit two guide pins in the holes. This will facil- Article number is specified in Required
itate the removal of the complete arm system equipment on page 181.
and prevent damage on the gearbox.

4 Repair
Continued
Action Note
14 Lift the complete arm system carefully and
secure it in a safe area. Note
CAUTION Make sure all hooks and attachments stay

in the correct position while lifting the arm
The lift must be done completely level! Make system and that the lifting accessory does
sure the roundslings are adjusted prior to not wear against sharp edges.
lifting the arm system.
Note
Continue lifting even if the arm system turns

out to be unbalanced despite earlier adjust-
ments! The risk of damaging the interface is
bigger if the load is lowered unbalanced!
CAUTION
Always move the robot at very low speed,

making sure it does not tip!
15 If needed, continue to remove the axis 1 See Replacing the axis 1 gearbox on
gearbox from the base. page 320.

4 Repair
Continued
Fitting the lifting accessories to the complete arm system
C
xx1100000249
A Shackle
B Lifting eye, M12
C Adapter
Action Note
1 Fit a roundsling from the frame to the over-
head crane.
2 Fit a roundsling from the lower arm to the
overhead crane.
3 Fit a roundsling from the upper arm to the
overhead crane.
4 Fit the adapter to the oil plug hole for filling Art. no. is specified in Required equip-
oil into axis 1 gearbox. ment on page 181.
5 Fit a lifting eye and a shackle to the adapter. Art. no. is specified in Required equip-
ment on page 181.
6 Fit a roundsling between the lower arm and The roundsling will take the load of the
the shackle. frame during the lift of the arm system,
provided that the brake of axis 2 is re-
leased.

4 Repair
Continued
Refitting the complete arm system

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

ing area.
2 Refit the axis 1 gearbox, if it has been re- See Replacing the axis 1 gearbox on
moved. page 320.
3
CAUTION
The robot arm system weighs 750 kg.

accordingly!
4 Fit the roundslings as described in Fitting the

lifting accessories to the complete arm sys-
tem on page 185.
5 Stretch the roundslings so that they secure Adjust the length of each roundsling so
the weight of the arm system. that the lift is done completely level.
6 Lift the complete arm system and move it at
very low speed to the mounting site, making Note
sure it does not tip!
Make sure all hooks and attachments stay
Note in the correct position while lifting the arm
system and that the lifting accessory does
The refitting must be made completely level! not wear against sharp edges.
Make sure the roundslings are adjusted prior
to refitting the arm system.

4 Repair
Continued
Action Note
7 Fit two guide pins in the holes in the axis 1
gearbox, shown in the figure.
Tip
In order to make refitting easier it is recom-

mended to use two guide pins of different
lengths. Notice that longer guide pins than
140 mm will not be possible to remove after
refitting because of lack of space.
xx1100000257
Dimension is specified in Required

Note
Always use guide pins in pairs.
8 Look through the empty mounting hole of the

axis 1 motor to assist in aligning the as-
sembly during refitting of the complete arm
system.
9 Lower the complete arm system with guid-
ance from the guide pins previously fitted to CAUTION
the axis 1 gearbox.
This is a complex task to be performed
Note with utmost care in order to avoid injury
or damage!
The refitting must be made completely level! Use a crank to turn the gearbox in order
Make sure the roundslings are adjusted prior to find the right position for the holes.
to refitting the arm system.
10 Place the serrated lock washers on the attach- Reused screws can be used providing
ment screws. they are lubricated as described in Screw
joints on page 387.
Note
Check that the serrated lock washers are

turned the correct way. See figure!
xx0600003070
Parts:
A Serrated lock washer (24 pcs)
B Axis 1 gearbox
C Attachment screws M12x110 qual-
ity 12.9 gleitmo (24 pcs)

4 Repair
Continued
Action Note
11 Fit 14 of the 16 attachment screws before the
arm system is completely lowered.
This is done in order to be able to attach all
screws into the threads correctly.
12 Replace the guide pins with the remaining
attachment screws and secure the complete
arm system to the base with its attachment
screws and washers.
13 Lower the arm system completely.
14 Secure the complete arm system with its at- Tightening torque:
tachment screws. • 120 Nm.
15 Refit the cable harness in the base and the See Replacing cable harness, lower end
frame. (axes 1-3) on page 144.
16 Refit the axis 1 motor. See Replacing motor, axis 1 on page 293.
17 Refit the mechanical stop pin to the frame.
xx1000001302
A: Mechanical stop pin

18 Perform a leak-down test of the axis 1 gear- See Performing a leak-down test on
box. page 136.
19 Refill the axis 1 gearbox with lubricating oil. See Changing oil, axis-1 gearbox on
page 118.
20 Recalibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 363.
General calibration information is included
in section Calibration on page 353.
21
DANGER


4 Repair
4.4.1 Replacing the turning disk
4.4 Upper and lower arm
Location of turning disk

The turning disk is located in the front of the wrist housing as shown in the figure
below.
xx1100000132
Required equipment

Turning disk For spare part no. O-rings are not included!
see: Spare parts on
page 397.

4 Repair
Continued

O-ring 3HAB3772-65 (1pc) Must be replaced when replacing
21520431-20 (6 pcs) the turning disk!
Used to lubricate the o-rings.
Flange sealant 3HAC034903-001 Loctite 574
these procedures in the step-
by-step instructions below.
Removing, turning disk

Use this procedure to remove the turning disk.
Action Note
1 Run the robot to a position where the tilthouse is
best positioned for the turning disk to be replaced.
2 Rotate axis 6 to its calibration position.
Note
This is done in order to fascilitate

fitting of the turning disk in the
correct position.
xx1100000139
3
DANGER
Turn off all:

4 Remove any equipment fitted to the turning disk.

4 Repair
Continued
Action Note
5 Drain the axis 6 gearbox. See section
• Changing oil, gearbox axis
6 on page 126
6 Remove the attachment screws that secure the
turning disk.
xx1100000075
Shown in the figure Location of

turning disk on page 189.
7 Remove the turning disk.
xx1100000076
8 Foundry Plus:
Remove old flange sealant residues and other con-
tamination from the contact surfaces.

4 Repair
Continued
Refitting, turning disk

Use this procedure to refit the turning disk.
Action Note
1 Lubricate the o-ring of the turning disk with Art. no. is specified in Required equip-
grease and fit it to the turning disk. ment on page 189.
xx1100000140
xx0200000218
• A: Sealing surface, o-ring

4 Repair
Continued
Action Note
2 Put some grease on the o-rings (6 pcs) and fit
them in turning disk as shown in the figure.
xx1100000080
3 Locate the calibration mark on the turning disk

and place the turning disk at the tilthouse so
that the calibration mark matches the calibration
scale at the tilthouse.
The hole pattern of the turning disk allows the
turning disk to be fitted in three different rotated
positions. Matching the calibration marks
guarantees that the turning disk is fitted at the
correct turn, provided that the axis 6 was set
in calibration position before the turning disk
was removed!
xx1100000139
4 Foundry Plus:
Apply Loctite 574 flange sealant on the contact
surface.
xx1400000995

4 Repair
Continued
Action Note
5 Secure the turning disk with its attachment
screws.
xx1100000078
Attachment screws M10x25 quality 12.9

(6 pcs)
Tightening torque:
• 175 Nm
Reused screws may be used, providing
they are lubricated as detailed in sec-
tion Screw joints on page 387 before fit-
ting.
6 Perform a leak-down test of the gearbox axis Detailed in the section Performing a
6. leak-down test on page 136.
7 Refill the axis 6 gearbox with oil. See section
• Changing oil, gearbox axis 6 on
page 126
8 Refit any equipment removed during disas-
sembly to the turning disk.
9
DANGER


4 Repair
4.4.2 Replacing the tilthouse unit
Introduction
This section describes how to replace the tilthouse unit. The section consists of
these parts:
• Location of tilthouse unit on page 196
• Location of axes 2 and 3 sides of the robot on page 197
• X-ray view of the assembly of the tilthouse unit on page 199
• Press tool for removal of shaft on page 200
• Removing the tilthouse unit on page 203
• Premounting outer race of bearing and radial sealing, axis 2 side on page 209
• Refitting shafts on page 211
• Refitting lock nuts and the remaining parts on page 213

4 Repair
Continued
Location of tilthouse unit

The tilthouse unit is located as shown in the figure.
xx1100000213

4 Repair
Continued
Location of axes 2 and 3 sides of the robot

The figures shows the location of the axes 2 and 3 sides of the robot. See markings
on the lower arm (axis 2) and the parallel arm (axis 3). These two sides of the robot
will be referred to in the replacing procedures.
xx1100000214
Axis 2 side (See marking on lower arm)

4 Repair
Continued
xx1100000215
Axis 3 side (See marking on parallel arm)

4 Repair
Continued
X-ray view of the assembly of the tilthouse unit

The figure shows a X-ray view of how the tilthouse unit is fitted to the upper arm.
Both sides looks the same.
xx1100000216
A Shaft
B Radial sealing
C Bearing
D Lock nut
E VK cover 65x8
VK cover 19x6 (Inside VK cover 65x8), not shown in this figure
Required equipment

VK cover Spare parts on page 397 VK 19x6 (2 pcs)

4 Repair
Continued

VK cover Spare parts on page 397 VK 65x8 (2 pcs)
Sealing ring 3HAB3701-19 D=70/85 T=8 (2 pcs)
Taper roller bearing 3HAA2103-13
Press tool, premounting outer 3HAC077982-001 Hydraulic pressing accessory.
race bearing User instructions are en-
closed with the tool.
Press tool, replacing shaft 3HAC040029-001 Used for assembly and disas-
sembly.
Auxiliary shaft 3HAC040035-001 Used for disassembly of
shaft.
KM7 socket 3HAC040025-001
Grease 3HAB3537-1
Rust preventive Dinitrol 490
Locking liquid 3HAB7116-1 Loctite 243
below.
Press tool for removal of shaft

The press tool replacing shaft is used both for removal and refitting. See figure
how to use the tool depending on purpose. For art. no. see Required equipment
on page 199.
The press tool replacing shaft and auxiliary bushing applied as shown in the figure
is used to disassemble the shaft.

4 Repair
Continued
The press tool consists of the parts shown in the figure.
A B C D E F G H A
xx1100000252
A Thread washer (2 pcs)

B Auxiliary shaft (3HAC040035-001) Only used on removal.
C Shaft axis 2
D Upper arm
E Tilthouse
F Support bushing (3HAC040029-002)
G Hydraulic cylinder
H Threaded bar M16
Press tool for fitting of shaft

The press tool replacing shaft is used both for removal and refitting. See figure
how to use the tool depending on purpose. For art. no. see Required equipment
on page 199.
The press tool replacing shaft applied as shown in the figure is used to fit the shaft.
The press tool consists of the parts shown in the figure. NOTE! The thread washer

4 Repair
Continued
(shown as A) in the figure must be used when fitting the shaft. If not the shaft will
not be pressed in completely.
A B C D E F G H
xx1100000256
A Thread washer, 3HAC040029-001

B Upper arm
C Shaft axis 3
D Tilthouse
E Support bushing
F Hydraulic cylinder
G Thread washer
H Threaded bar M16

Action Note

4 Repair
Continued
Action Note
calibration:
Removing the tilthouse unit

Use this procedure to remove the tilthouse unit.
Action Note
take actions accordingly prior to beginning the
repair procedure.
2 Move the robot to a position where the tilthouse
rests on a workbench, pallets or similar.
xx1100000225

4 Repair
Continued
Action Note
3 This is done in order to prevent the tilthouse
from falling down when the upper link is re-
moved.
DANGER
If not secured the tilthouse will fall down when

the upper link is removed. See figure!
xx1100000226
4
DANGER
Turn off all:

area.
5 Secure the tilthouse with a roundsling in an

overhead crane or similar.
xx1100000227
6 Disconnect motor cables from motor axis 6. See Replacing motor, axis 6 on
Place the motor cables in a way that it will not page 312
be damaged.

4 Repair
Continued
Action Note
7 Disassemble the upper link arm from the tilt- See Replacing linkage - upper link arm
house unit. on page 233
Note
It is not needed to remove the upper link from

the link.
xx1100000228
8 Remove one of the M6 screws and washer for

filling grease.
xx1100000230

4 Repair
Continued
Action Note
9 Be careful not to damage the ball plug!
Note
Do not remove the ball plug!
xx1100000231
10 Remove one shaft at a time by following the

steps below, starting on axis 2 side.
11 Use compressed air in the M6 hole for filling
grease, in order to remove the VK cover.
Put a hand with some paper over the VK cover
in order to catch it.
CAUTION
Only a very low air pressure is needed!
xx1100000232

4 Repair
Continued
Action Note
12 Remove the small VK cover from the inside
with the help of a short punch or similar.
xx1100000233
Parts:
A: VK cover
B: Punch
13 Remove the lock nut.
xx1100000234
14 Apply the press tool shaft and auxiliary bushing For art.no:s. see Required equipment
used for removing the shaft, as shown in the on page 199.
figure in: The longer threaded bar: M16 length
• Press tool for removal of shaft on 450 mm
page 200
Note
A longer threaded bar M16 is needed when re-

moving the shaft than the one specified when
fitting.

4 Repair
Continued
Action Note
15 Press out the shaft with the press tool.
xx1100000235
16 Remove the press tool shaft and the shaft.
xx1100000236
17 Check that the tilthouse is secured in an over-

head crane or similar before proceeding with
the next shaft.
18 Remove the shaft on the axis 3 side in the same
way by following the steps above.
19
CAUTION
The robot tilt house weighs 50 kg.

All lifting accessories used must be sized ac-
cordingly!

4 Repair
Continued
Action Note
20 Remove the tilthouse and lift it to a safe place.
Check that bearings are kept clean. Replace if
damaged.
xx1100000237
21 Force away the sealing ring with a screwdriver

or similar.
The sealing ring must be replaced with new
ones when refitting.
xx1100000243
22 If needed replace bearings.
Premounting outer race of bearing and radial sealing, axis 2 side

Use this procedure to fit the outer race of the bearing and radial sealing in the
tilthouse on the axis 2 side, before fitting the tilthouse to the upper arm.
Action Note
1 This work is best done on a workbench or sim-
ilar.
2 Fit the radial sealing in the hole.
3 Apply some grease in the hole for the bearings. Art.no. is specified in Required equip-
ment on page 199.

4 Repair
Continued
Action Note
4 Fit the outer race of the bearing. Normally this For art.no. see Required equipment
can be done by hand. on page 199.
If needed apply the press tool pre-mounting
bearing and fit the outer race of the bearing. Note
Check that the races are turned the

correct way!
xx0900000813
Go to the user instructions enclosed with the

press tool.
DANGER
Handling the tool incorrectly will cause serious B

injury. A
Read and follow enclosed user instructions for
the tool.
xx1100000244
Parts:
A: Surface for VK cover
B: Outer race bearing axis 2
side
5 Apply grease on the inner diameter of the radial Also see
sealing.
Premounting outer race of bearing and radial sealing, axis 3 side

Use this procedure to fit the outer race of the bearing and radial sealing in the
tilthouse on the axis 3 side, before fitting the tilthouse to the upper arm.
Action Note
1 This work is best done on a workbench or sim-
ilar.
2 Fit the radial sealing in the hole. See X-ray view of the assembly of the
tilthouse unit on page 199.
3 Apply some grease in the hole for the bearings. Art.no. is specified in Required

4 Repair
Continued
Action Note
4 Fit the outer race of the bearing. Normally this Art.no. specified in Required equip-
can be done by hand. ment on page 199.
If needed apply the press tool pre-mounting
bearing and fit the outer race of the bearing.
xx0900000813

press tool.
DANGER
Handling the tool incorrectly will cause serious

injury. A
Read and follow enclosed user instructions for
the tool. B
xx1100000245
Parts:
A: Outer race bearing axis 3
side
B: Surface for VK cover
5 Apply grease on the inner diameter of the radial See X-ray view of the assembly of the
sealing. tilthouse unit on page 199.
Refitting shafts
Before starting this procedure, prepare the tilthouse as described in:
Use this procedure to refit the shafts of the tilthouse unit.
Action Note
1
CAUTION
The robot tilt house weighs 50 kg.

cordingly!

4 Repair
Continued
Action Note
2 Secure the tilthouse with a roundsling in an
overhead crane or similar and lift it to its
mounting position on the upper arm and let it
rest on a workbench, some pallets or similar
(as when removing it).
xx1100000227
3 Apply rust preventive (Dinitrol 490) on the sur-

face where the tilthouse faces the upper arm.
B
C
xx1100000248
Parts:
A: Dinitrol 490
B: Tilthouse
C: Upper arm
4 Apply some grease in the hole for the shaft in Art. no. is specified in Required
the upper arm. equipment on page 199.
5 See Location of axes 2 and 3 sides of
Note the robot on page 197.
Refit the axis 2 side first!

4 Repair
Continued
Action Note
6 Push the shaft into its hole, from the inside. The figure shows IRB 760 but the
principle is the same.
xx1000001438
7 Align the holes in the upper arm and tilthouse

as close as possible.
8 Apply the press tool shaft prepared for refitting
the shaft, as shown in the figure in:
NOTE! Use the correct thread washer pressing
against the shaft. See figure! If the correct
thread washer isn't used, the shaft will not be
pressed in completely.
• Press tool for fitting of shaft on page 201.
9 Press the parts together.
10 Fit the axis 3 side in the same way, by following
the steps above.
Refitting lock nuts and the remaining parts

Before starting this procedure, perform the procedure:
• Refitting shafts on page 211
Use this procedure to refit the lock nuts and the other remaining parts of the
tilthouse unit.
Action Note
1
Note
Start the assembly on the axis 2 side!

4 Repair
Continued
Action Note
2 Place the inner race of the bearing on the shaft
on the axis 2 side and push it in position.
Note
Normally it shall be possible to fit the bearing

into position very easy.
3 Apply locking liquid (Loctite 243) on the threads

of the lock nut KM7.
4 Secure the axis 2 shaft with the lock nut. Tightening torque:
• 90 Nm
Note
Flat side of the lock nut facing inwards!
5 Place the inner race of the bearing on the shaft

on the axis 3 side and push it in position.
Note
Normally it shall be possible to fit the bearing

into position very easy.
6 Apply locking liquid (Loctite 243) on the threads

of the lock nut KM7.
7 Secure the axis 3 shaft with the lock nut. Tightening torque: 90 Nm.
Note Note
Flat side of the lock nut facing inwards! Rotate the tilthouse while securing the
lock nut on the axis 3 side.
8 Wipe clean the sufaces for the VK-covers with

Isopropanol.
9 Fit the small VK covers on axes 2 and 3 using
a plastic mallet.
10 Fit the big VK covers on axes 2 and 3 using a
plastic mallet.
11 Fill bearings with grease by removing both M6
screws on either side. One hole is used for
filling and the other for letting out air. Fill until
grease spills out of the air hole.
12 Fit the M6 screws and washers covering the
grease filling holes.
13 Refit the upper link arm. See Replacing linkage - upper link arm
on page 233
14 Refit the motor cable, axis 6. See Replacing motor, axis 6 on
page 312

4 Repair
Continued
Action Note
Operating manual - Calibration Pendu-
lum, enclosed with the calibration
tools.
Axis Calibration is described in Calib-
rating with Axis Calibration method on
page 363.
General calibration information is in-
cluded in section Calibration on
page 353.
16
DANGER


4 Repair
4.4.3 Replacing the upper arm
Location of the upper arm

The upper arm is located as shown in the figure.
xx1100000262
Different versions of the sealing structure

Robots that are delivered from October 2012 and forward has a new sealing
structure at the link that consists of a support ring, o-ring and radial sealing.
Robots delivered before October 2012 has a sealing structure that consists of a
POM sealing, if not updated with the new sealing structure according to above.
The removal and refitting procedures describe both versions of sealing structures.
The steps that differ are marked with information about which sealing structure
the step is valid for.

4 Repair
Continued
Cut away view of the assembly of the upper arm components

The figure shows a cut away view how the upper arm is fitted to the lower arm.
Design with POM sealing
A B C D E F G H J K
xx1100000273
A Lock nut
B Support ring
C Sealing ring (V-ring)
D Lower arm
E Bearing
F T-ring
G Sealing ring (V-ring)
H Shaft
J Bushing
K Upper arm

4 Repair
Continued
Design with support ring
xx1300000013
A Lock nut
B Support ring
C Sealing ring (V-ring)
D Lower arm
E Bearing
F T-ring
G Sealing ring (V-ring)
H Shaft
J Bushing
K Upper arm
Press tool, upper arm

The press tool upper arm is used to assemble T-ring and bearing in the upper arm.
For art. no. see Required equipment on page 220.

4 Repair
Continued
The same tool is used for removal and refitting but some parts are different. See
figure!
J
H
A B C D E F G
xx1100000269
A Threaded bar M16

B Thread washer (3HAC040021-004)
C Hydraulic cylinder (3HAC040021-005)
D Press bushing (3HAC040026-003). Only used at assembly.
E Auxiliary shaft (3HAC040026-002)
F Shaft
G Bearing
H Lower arm
J Upper arm

4 Repair
Continued
Pull tool, shaft

The pull tool shaft is used to remove the shaft, bearing and T-ring in the upper arm.
For art. no. see Required equipment on page 220.
The pull tool shaft is using the same parts as the press tool upper arm but the
press bushing is replaced by the support bushing. See part marked red in the
figure.
A B C D E F G
xx1100000270
A Threaded bar M16

B Thread washer
C Hydraulic cylinder
D Support bushing (3HAC040026-004). Only used at removal.
E Auxiliary shaft (3HAC040026-002)
F Shaft
G Bearing
H Lower arm
J Upper arm
Required equipment

Upper arm, axis 4 For spare part no. see: Includes:
• Spare parts on page397 • 3HAC037314-001
bushing (2 pcs)
V-ring 2216264-16
T-ring 3HAC022581-001
Adapter 3HAC040027-001 The adapter consists of two
parts: the adapter and a pro-
tective cover. Always use the
protective cover together with
the adapter!
Press tool, support ring 3HAC072616-001 Used to press in new support
rings in the upper arm hous-
ing, if damaged.

4 Repair
Continued

Press tool, upper arm 3HAC040026-001 Including:
• 3HAC040021-004
Thread washer
• 3HAC040021-005 Hy-
draulic cylinder
• 3HAC040026-003
Press bushing
• 3HAC040026-002 Aux-
iliary shaft
Support, bushing 3HAC040026-004 When used with the parts
from Press tool upper arm
this tool is called Pull tool,
shaft.
The only difference is that the
press bushing is replaced by
the support bushing.
Socket, KM 12 3HAC040023-001
Bearing grease 3HAB3537-1
Lubricant paste Molycote 1000
below.

Action Note

4 Repair
Continued
Action Note
calibration:
Preparations before removing the shafts of the upper arm

Use this procedure to do the necessary preparations before removing the upper
arm.
Action Note
2 Remove all equipment fitted to upper arm
and tilthouse unit.
3 Jog axes 2 and 3 to the following positions:
Axis 2: +40 degrees.
Axis 3: -40 degrees.
4
DANGER
Turn off all:

ing area.
5 Remove the cable harness in the upper arm. See section

• Replacing the cable harness, upper
end (incl. axis 6) on page 154
6
CAUTION
The robot upper arm weighs 120 kg.

accordingly!
7 Secure the upper arm with a roundsling in an

8 Raise the lifting equipment to take the weight
of the upper arm.
9 Remove the linkage system. See section
• Replacing linkage - upper link arm
on page 233
• Replacing linkage - lower link arm
on page 241
• Replacing the linkage - link on
page 248
10 Remove the tilthouse unit. See section
• Replacing the tilthouse unit on
page 195

4 Repair
Continued
Action Note
11 Remove the parallel rod. For more information, see Replacing
parallel rod on page 265.
Removing the upper arm- part 1

Use this procedure to remove the upper arm - part 1.
Action Note
1 Remove the lock nuts (KM12) securing the
shafts on axis 2 and axis 3 sides.
Note
Remove lock nuts on axis 2 and 3 sides!
xx1100000266
2 Remove the Radial seal, sleeve and O-ring

from the shaft.
Note
Remove Radial seal, sleev and O-ring on both

axis 2 and 3 sides!
xx1100000267
Parts:
• A: Radial seal with dust lip
• B: Sleeve
• C: O-ring

4 Repair
Continued
Action Note
3 Remove the set screws securing the axis 2
and 3 shafts. One on each shaft.
xx1100000263
4 Place the adapter (including the protection

cover) on the shaft.
The adapter consists of two parts: the adapter
and a protective cover. Always fit the protect-
ive cover to the adapter when using the ad-
apter!
xx1100000264
xx1100000265
• A: Protective cover
• B: Adapter
Removing the upper arm - part 2

Use this procedure to remove the upper arm - part 2.
Action Note
1 Start the continued removal of shafts on the
axis 3 side.
2 NOTE!
The axis 3 shaft must be removed in more
than one step. The reason is the fitting of the
outer race of the bearing is very tight.

4 Repair
Continued
Action Note
3 Begin by carefully applying torque to release
the shaft of axis 3.
NOTE!
Perform this move with care. Threads can
otherwise be damaged.
4 Continue releasing the shaft until the gap
between the upper and lower arms on the
axis 2 side has disappeared.
NOTE!
The shaft at this point still connects to the
upper arm through the threads.
5 Apply the pull tool shaft and pull the shaft TIP!
with bearing and T-ring out, until the gap Use a bar or similar to push the upper arm
between upper and lower arms on the axis 3 against the axis 3 side during the pulling
side disappears. out of the shaft. Insert the bar into the gap
on the axis 2 side.
6 Remove the pull tool shaft and apply the ad-
aptor on the shaft.
7 Continue releasing the shaft from the upper The upper arm will start to move against
arm using the adaptor. the axis 2 side again.
Release until the gap between lower and up-
per arms on the axis 2 side disappears again.
8 Check that the threads on the shaft and the If the answer is "No", repeat the steps
upper arm are completely separated. above to make sure the threads of the
shaft and the upper arm are completely
separated, before continuing.
9 If the answer is "Yes" pull the shaft out com-
pletely together with bearing and T-ring using
the pull tool shaft.
10 Put the shaft in a clean and safe place.
11
DANGER
Before continuing check that the upper arm

is secured in an overhead crane or similar.
With axis 3 removed there will be no support
for the upper arm.
12 Remove the axis 2 shaft by following the

steps above.
13 Remove the upper arm.
14 Check the V-ring! Replace if damaged!
Preparations of the shafts before refitting the upper arm

Use this procedure to do the necessary preparations of shafts and bearings before
refitting the upper arm.
Action Note
1 This procedure is best performed on a work-
bench or similar.
2 Place the shafts on the workbench.

4 Repair
Continued
Action Note
3 Fit the sealing ring (V-ring) on the shaft.
xx1100000268
Parts:
• A: Shaft
• B: Sealing ring (V-ring)
4 Apply some grease on shafts and sealing
rings. Note
Do not apply grease on threads and

cones of the shafts. See area marked red
in the figure above!
5 Fill bearings with bearing grease.

Note
Rotate the bearing during filling grease

to make sure the lubrication for both outer
and inner races are good.
6 Apply lubricant paste (Molycote 1000) on

threads and cones of the shafts.
Preparations before refitting the shafts of the upper arm

Use this procedure to do the necessary preparations before refitting the shafts.
Action Note
1
CAUTION
The robot upper arm weighs 120 kg.

accordingly!
2 Secure the upper arm with a roundsling in an


4 Repair
Continued
Action Note
3 Check that the bushings in the upper arm are
without damages and still in the correct posi-
tion.
Note
If damaged, replace the bushing!
xx1100000271

4 Repair
Continued
Action Note
4 Valid for design with support rings. Art. no. is specified Required equipment
Check the support rings in the upper arm. on page 220
If they are damaged, replace them accord-
ingly:
1 Fit a support ring to the press tool and
lubricate with grease for easier as-
sembly.
2 Press in the support ring to the upper
arm housing by screwing on the press
tool assembly. Tighten with 120 Nm.
3 Remove the press tool. The support
ring is now fitted to the upper arm
housing.
4 Repeat the procedure on the other
side.
xx1900001713
CAUTION
If the support ring is mounted askew, there

is a risk of play between the shaft and the
upper arm. Make sure the support rings are
aligned correctly (level) inside the upper arm
housing.
xx1900001714
xx1900001205
5 Move the upper arm to its mounting position.

Make sure that the upper arm is placed in a Note
horizontal position.
Make sure that the upper arm is placed
correctly in a way that the shafts can be
inserted without being damaged!
Refitting the upper arm shafts

Use this procedure to refit the upper arm shafts.
Action Note
1 NOTE!
Refit the shaft on the axis 3 side first!

4 Repair
Continued
Action Note
2 Carefully fit the shaft into the threads of the
upper arm, by hand only.
Note
Do not use force since threads otherwise can

be damaged!
3 Place the adapter (including the protection

cover) on the shaft.
The adapter consists of two parts: the adapter
and a protective cover. Always fit the protect-
ive cover to the adapter when using the ad-
apter!
xx1100000264
xx1100000265
• A: Protective cover
• B: Adapter
Secure the shaft.
4 Place the T-ring on the shaft by hand as close A B C D
to its final position as possible.
xx1100000274
Parts:
• A: Lower arm
• B: T-ring
• C: Surface on lower arm on which
the T-ring rests against
• D: Shaft

4 Repair
Continued
Action Note
5 Place the outer race of the bearing on the
shaft as close to its final position as possible.
xx1100000276
Parts:
• A: Lower arm
• B: Outer bearing
• C: Surface on T-ring on which out-
er race rests against
• D: T-ring
• E: Shaft
6 Apply the press tool upper arm and press See the figures above!
both parts into their final position.
Note
Make sure that the T-ring is pressed in all the

way and rests against the lower arm correctly.
See figure!
Note
Make sure the bearing is pressed in all the

way and rests in the correct position on the
shaft. See figure!
7 Fill the inner race of the bearing with grease.

8 Fit the inner race of the bearing on the shaft
and press it in using the press tool upper arm.
Note
Make sure the bearing is pressed in all the

way and rests in the correct position on the
shaft. See figure!
xx1100000275
Parts:
• A: Lower arm
• B: Bearing inner race
• C: Surface on shaft on which the
inner race of bearing rests against
• D: T-ring
• E: Shaft

4 Repair
Continued
Action Note
9 Fit the O-ring, Sleeve and Radial seal.
xx1100000267
Parts:
• A: Radial seal with dust lip
• B: Sleeve
• C: O-ring
10 Only applicable to the axis 3 side!
Secure the shaft with the lock nut on the axis
3 side by following this order:
1 Apply locking liquid (Loctite 243) on
the threads of the lock nut.
2 Tighten the lock nut with a tightening
torque of 90 Nm.
NOTE!
Notice the different procedures for axis 3 and
axis 2 sides!
11 Only applicable to the axis 2 side! NOTE!
Secure the shaft with the lock nut on the axis Moving the upper arm while tightening
2 side by following this order: the lock nut is important for a correct fit!
torque of 200 Nm. Move the upper arm
while applying the torque.
2 Unscrew the lock nut
3 Apply locking liquid (Loctite 243) on
the threads of the lock nut.
torque of 90 Nm. Move the upper arm
while applying the torque.
NOTE!
Notice the different procedures for axis 3 and
axis 2 sides!
12 Refit the shaft on the axis 2 side, by following
the steps in this procedure.

4 Repair
Continued
Refitting the upper arm - concluding procedures

Use this procedure for the concluding refitting of the upper arm.
Action Note
1 Apply locking liquid (Loctite 243) in the two
holes for the set screws and fit the screws.
xx1100000263

2 Wipe residual grease and contamination off
the shafts.
3 Refit the tilthouse unit. See Replacing the tilthouse unit on
page 195.
4 Refit the parallel rod. See Replacing parallel rod on page 265.
5 Refit the cable harness in the upper arm. See section
• Replacing the cable harness, upper
end (incl. axis 6) on page 154
6 Refit the linkage system starting with the link. Also see
on page 233
on page 241
page 248
page 363.
8
DANGER


4 Repair
4.4.4 Replacing linkage - upper link arm
Overview
The linkage consists of three basic parts - upper link arm, lower link arm and link.
This procedure describes how to remove and refit the upper link arm.
How to replace lower link arm and link see:
• Replacing linkage - lower link arm on page 241
• Replacing the linkage - link on page 248
Location of upper link arm

The upper link arm is located as shown in the figure.
xx1100000167
A Upper link arm

B Link
C Lower link arm

4 Repair
Continued
Required equipment
Equipment Art no. Note

Upper link arm For spare part no. see:
• Spare parts on page397
Spherical roller bearing For spare part no. see: Replace if damaged.
• Spare parts on page397 (2 pcs)

Bearing puller Bearing puller with three legs.
below.
Removing the upper link arm

Use this procedure to remove the upper link arm.
Action Note
1 Put the robot in a position where it is possible Check especially that it is possible to re-
to reach all parts that shall be removed. move the locking washer at the link.
2 Let the tilthouse rest on a workbench, on
some pallets or similar.
This is done in order to prevent the tilthouse
from falling downwards when the upper link
arm is removed.
CAUTION
In order to avoid accidents, also secure the

upper arm in an overhead crane.
xx1000001132

4 Repair
Continued
Action Note
3
CAUTION
If the lower link arm is removed, secure the

link with a roundsling in an overhead crane.
Use the hole in the middle of the link.
This is done in order to prevent the link from
moving if both the upper and lower link arms
are removed.
xx1100000173
4
DANGER
Turn off all:

ing area.

4 Repair
Continued
Action Note
5 Remove the lock screw securing the locking
washer.
xx1100000170
Parts:
A Lock screw
B Locking washer
6 Remove the locking washer.
xx1100000171

4 Repair
Continued
Action Note
7 Remove the upper link arm as shown in the
figure.
A three legged bearing puller will be needed
to remove the link arm from the link. To re-
move it from the tilthouse a plastic mallet can
be used.
xx1100000169
8 Remove the radial sealing rings.
xx1100000172
Parts:
A Radial sealing ring
B Bearing
C Radial sealing ring
9 Remove residual grease.

4 Repair
Continued
Refitting the upper link arm

Use this procedure to refit the upper link arm.
Action Note
1 If needed, replace the bearings in the upper
link arm.
Note
The bearings are sensitive for pushes. Make

sure they are not damaged!
2 Lubricate the bearings properly with bearing

grease.
3 Fit radial sealing rings in the upper link arm
as shown in the figure.
xx1100000172
Parts:
B Bearing

4 Repair
Continued
Action Note
4 Place the locking washer in the upper link
arm.
xx1100000171
5 Apply a bearing puller with three legs and Check that the upper link arm is pushed
press the upper link arm on to the shaft. completely in position.
Note
The press force shall be applied on the lock-

ing washer.
6 Apply locking liquid on the lock screw. Loctite 243.

4 Repair
Continued
Action Note
7 Secure the locking washer with the lock Tightening torque: 25 Nm.
screw.
xx1100000170
Parts:
A Lock screw
B Locking washer
8
DANGER


4 Repair
4.4.5 Replacing linkage - lower link arm
Overview
The linkage consists of three basic parts - upper link arm, lower link arm and link.
This procedure describes how to remove and refit the lower link arm.
How to replace the upper link arm arm and link see:
• Replacing linkage - upper link arm on page 233
• Replacing the linkage - link on page 248
Location of lower link arm

The lower link arm is located as shown in the figure.
xx1100000167
A Upper link arm

B Link

4 Repair
Continued
C Lower link arm
Required equipment
Equipment Art no. Note

Lower link arm For spare part no. see:
Spherical roller bearing For spare part no. see: Replace if damaged.
• Spare parts on page397 2 pcs
Bearing grease 3HAB3537-1 Tribol GR 100-2 PD

Bearing puller Bearing puller with three legs.
Standard toolkit Content is defined in section
below.
Removing the lower link arm

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

ing area.

4 Repair
Continued
Action Note
2
CAUTION
If the upper link arm is removed, secure the

link with a roundsling in an overhead crane.
This is done in order to prevent the link from
moving if both the upper and lower link arms
are removed.
xx1100000173
3 Remove the lock screw securing the locking

washer.
xx1100000170
Parts:
A Lock screw
B Locking washer

4 Repair
Continued
Action Note
4 Remove the locking washer.
xx1100000171
5 Remove the lower link arm by lifting it straight

out.
A three legged bearing puller will be needed
to remove the link arm from the link. To re-
move it from the frame a plastic mallet can
be used.
Note
If needed use a plastic mallet to remove the

lower link arm.
xx1100000174

4 Repair
Continued
Action Note
6 Remove the radial sealing rings.
xx1100000172
Parts:
B Bearing
7 Remove residual grease and sealing com-
pound.
Refitting the lower link arm

Use this procedure to refit the lower link arm.
Action Note
1 If needed, replace the bearings. Spare part no. is specified in Required
Note
The bearings are sensitive for pushes. Make

sure they are not damaged!
2 Lubricate the bearings properly with bearing For art. no. see Required equipment on
grease. page 242.

4 Repair
Continued
Action Note
3 Fit the radial sealing rings in the lower link
arm as shown in the figure.
xx1100000172
Parts:
B Bearing
4 Place the locking washer in the lower link
arm.
xx1100000171
5 Apply a bearing puller with three legs and Check that the lower link arm is pushed
press the lower link arm on to the shaft. completely in position.
Note
The press force shall be applied on the lock-

ing washer.

4 Repair
Continued
Action Note
6 Apply locking liquid on the lock screw. Loctite 243
7 Secure the locking washer with the lock Tightening torque: 25 Nm.
screw.
xx1100000170
Parts:
A Lock screw
B Locking washer
8
DANGER


4 Repair
4.4.6 Replacing the linkage - link
Overview
The linkage consist of three basic parts - upper link arm, lower link arm and link.
This procedure describes how to remove and refit the link.
How to replace the upper and lower link arms see:
• Replacing linkage - upper link arm on page 233
• Replacing linkage - lower link arm on page 241
Location of link
The link is located as shown in the figure.
xx1100000167
A Upper link arm

B Link
C Lower link arm

4 Repair
Continued
Different versions of the sealing structure

Robots that are delivered from October 2012 and forward has a new sealing
structure at the link that consists of a support ring, o-ring and radial sealing.
Robots delivered before October 2012 has a sealing structure that consists of a
POM sealing, if not updated with the new sealing structure according to above.
The removal and refitting procedures describe both versions of sealing structures.
The steps that differ are marked with information about which sealing structure
the step is valid for.
X-ray view of the assembly of the link

The figure shows an X-ray view of the assembly of the link.
Design with POM sealing
xx1100000212
A VK cover
B Lock nut
C Bearing
D Bearing
E POM Sealing

4 Repair
Continued
Design with support ring
xx1300000007
A VK cover
B Lock nut
C Bearing
D Bearing
E Support ring, including o-ring
F Radial sealing
Required equipment

Link For spare part number, see:
Bearing Replace if damaged.
Radial sealing i Replace if damaged.
Support ring i Replace if damaged.
O-ring i Replace if damaged.
Auxiliary shaft 3HAC040022-002 Used for bearings.
Press tool link (bearing outer 3HAC077981-001 Hydraulic pressing accessory
races) used to press the outer reces
of the bearings in the link.
User instructions are en-
Press tool support 3HAC040031-001
Press tool, link 3HAC040022-001 Used to fit the link.
Socket KM 8 3HAC040024-001
4 Repair
Continued

Bearing puller - Used to remove the link.
Locking liquid i 12340011-116 Loctite 574
Grease 3HAB3537-1
below.
i Valid for design with support ring.

Action Note
calibration:
Removing the link

Use this procedure to remove the link.
Action Note

4 Repair
Continued
Action Note
2
DANGER
Turn off all:

ing area.
3 Secure the link with a roundsling in an over-

head crane.
CAUTION
This is done to prevent the link from moving

when the upper and lower link arms are re-
moved which can cause an accident.
xx1100000173
4 Remove upper and lower link arms. How to remove upper link arm see:
on page 233
How to remove lower link arm see:
on page 241

4 Repair
Continued
Action Note
5 Remove screw and washer in the hole for
filling grease.
xx1100000196
6 Use compressed air to remove the VK cover.

Blow with a very low air pressure into the hole
for filling grease.
Put one hand with some paper on top of the
VK cover in order to catch it when it is re-
leased.
CAUTION
Only a very low air pressure is needed!
xx1100000195

4 Repair
Continued
Action Note
7 Remove the lock nut (KM8).
xx1100000197
8 Fit the auxiliary shaft on the shaft of the link.

9 Put the end of the link which is facing the Normally a not too hard knock is needed
upper rod, downwards in order to find room to loosen the link.
to knock on it with a plastic mallet from the If needed use a bearing puller to remove
inside. the link.
Knock on the link as close as possible to its
center.
Note
Loosen the lifting force a little before start

knocking. If not the link can be locked by the
lifting power.
xx1100000198
10 Use a pair of levers or apply a bearing puller

and bend the link loose.
11 Remove the link.

4 Repair
Continued
Action Note
12 Remove the POM sealing or the support ring
(depending on version of sealing structure).
xx1100000199
13 Wipe off residual grease.

14 Valid for design with support ring.
Remove the radial sealing from the link, if the
link is to be replaced with a new spare part.
Replace the radial sealing, if damaged.
15 If needed, replace bearings.
Fitting outer races of the bearings in link
Action Note
1 Put the link on a workbench.
2 Fit the new outer races using the mounting Art. no. is specified in Required equip-
tool. ment on page 250
xx0900000813

press tool.
DANGER
Handling the tool incorrectly will cause seri-

ous injury.
Read and follow enclosed user instructions
for the tool.

4 Repair
Continued
Refitting the link

Use this procedure to refit the link of the linkage.
Action Note
Place the radial sealing in the link.
xx1300000006

Place the o-ring inside the groove of the
support ring.
xx1300000005
3 Valid for design with support ring. Loctite 574

Apply locking liquid on the inner surface of
the support ring.
xx1300000008

4 Repair
Continued
Action Note
Fit the support ring with the included o-ring
on the shaft. Use a plastic mallet, if neces-
sary.
Note
Align the chamfer side of the support ring

with the shaft shoulder as shown in figure.
xx1300000004
5 Valid for design with POM sealing.

Place the POM sealing on the shaft.
xx1100000200
6 Secure the link with a roundsling in an over-

head crane and lift it to the mounting position.
7 Fit the auxiliary shaft on the shaft. Art.no. is specified in Required equipment
on page 250

4 Repair
Continued
Action Note
8 Place the inner race of the inner bearing on Art, no, is specified in Required equip-
the shaft and press it in position using the ment on page 250.
press tool link.
xx1100000201
Auxiliary shaft not shown in this figure.

9 Place the inner race of the outer bearing and
link, in the following order on the shaft:
• link
• bearing
xx1100000202
Parts:
A: Inner race of outer bearing
B: Link
C: Inner bearing complete
10 Press the parts together with the press tool, Art.no. is specified in Required equipment
link. on page 250.

4 Repair
Continued
Action Note
11 Apply locking liquid on the lock nut. Loctite 243
xx1100000197
12 Secure the lock nut in these three steps:

1 Tighten with a torque of 300 Nm, while Note
rotating the link at the same time.
2 Unscrew the lock nut The recommended order of tightening the
3 Tighten the lock nut finally with a lock nut is important to follow to avoid
tightening torque of 90 Nm. future problems with the shaft.
13 Valid for design with POM sealing.

Use a screwdriver carefully to fit the POM
sealing into its final position.
xx1100000204

4 Repair
Continued
Action Note
14 Refit the VK cover.
xx1100000205
15 Make sure the vent hole is open.
xx1900001001
A Vent hole

4 Repair
Continued
Action Note
16 Fill the link with grease. Art.no. is specified in Required equipment
on page 250
xx1900000923
B Hole for filling grease

4 Repair
Continued
Action Note
17 Refit the screw and washer in the hole for
filling grease and the vent hole.
xx1900000924
xx1100000196
18 Refit the upper link arm. See section Replacing linkage - upper link
arm on page 233
19 Refit the lower link arm. See section Replacing linkage - lower link
arm on page 241

4 Repair
Continued
Action Note
20 Recalibrate the robot! Pendulum Calibration is described in
page 363.
21
DANGER


4 Repair
4.4.7 Replacing the POM sealing for the link system
4.4.7 Replacing the POM sealing for the link system
Overview
The linkage consist of three basic parts - upper link arm, lower link arm and link.
How to replace the POM sealing is described in the same section as how to replace
the link, see Replacing the linkage - link on page 248.
X-ray view of the assembly of the link

The figure shows a X-ray view of the assembly of the link.
xx1100000212
A VK cover
B Lock nut
C Bearing
D Bearing
E POM Sealing

4 Repair
4.4.8 Replacing parallel rod
Location of the parallel rod

The parallel rod is located as shown in the figure.
xx1100000164
Required equipment

Parallel rod For spare part no. see:
Mounting/Demounting tool 3HAC040021-001

4 Repair
Continued

below.
How to apply the mounting/demounting tool for removal

This figure shows how to apply the mounting/demounting tool when removing the
parallel rod. For art. no. see Required equipment.
xx1100000166
A Thread bush
B Support bush
D Thread washer
Removing the parallel rod

Use this procedure to remove the parallel rod. The procedure is the same in both
ends.
Action Note
1
DANGER
Turn off all:

ing area.
2
CAUTION
In order to avoid accidents secure the upper

arm with a roundsling in an overhead crane
or similar.

4 Repair
Continued
Action Note
3 Remove the lock screw and washer, securing
the shaft of the parallel rod in position.
xx1100000141

4 Repair
Continued
Action Note
4 Apply a shims (T= 8 mm) on axis 3 side, as
shown in the figure to the right.
.
xx1100000142
A
xx1100000030
A: Thickness = 8 mm.
5 Apply the mounting/demounting tool to the For art. no. see:
shaft. • Required equipment on page 265

4 Repair
Continued
Action Note
6 Remove the upper shaft.
xx1100000144
7 Move the parallel rod backwards from its up-

per connection point and let it rest against
the base.
xx1100000146

4 Repair
Continued
Action Note
8 Remove the thrust washer with a POM seal-
ing fitted on the axis 2 side.
xx1100000145
Parts:
• A: Thrust washer
• B: Bearing
• C: POM sealing fitted on thrust
washer (axis 2 side)
• D: POM sealing (axis 3 side)
9 Remove the POM sealing on the axis 3 side. See figure above!
10 Remove the lower end of the parallel rod in
the same way as the upper end
11 Remove the parallel rod from the robot.
12 Replace the bearings, if necessary.
How to apply the mounting/demounting tool for refitting

This figure shows how to apply the mounting/demounting tool when refitting the
parallel rod. For art. no. see Required equipment.
xx1100000165
A Thread bush
B Support bush
4 Repair
Continued
D Tread washer
Refitting the parallel rod

Use this procedure to refit the parallel rod. The procedure is the same in both ends.
Action Note
1 Start refitting the lower end of the parallel
rod.
2 Make sure the bearings are in the correct
position in the parallel rod.
3 Fit a POM sealing on the thrust washer.
xx1100000148
• A: Thrust washer
• B: POM sealing
4 Put the thrust washer (with a POM sealing
fitted) on the axis 2 side of the parallel rod.
xx1100000149

4 Repair
Continued
Action Note
5 Place the other POM sealing on the axis 3
side.
xx1100000151
6 Place the parallel rod in its mounting posi-

tion in the lower end.
xx1100000161

4 Repair
Continued
Action Note
7 Apply a shims (T= 8 mm) on the axis 3 side,
as shown in the figure to the right.
Do not press the shims down too far.
xx1100000142
A
xx1100000030
A = Thickness 8 mm
8 Refit the shaft using the mounting/demount-
ing tool.
xx1100000162

4 Repair
Continued
Action Note
9 Apply locking liquid in the hole of the lock Loctite 243
screw.
xx1000001349
10 Refit the lock screw and plain washer. Lock screw: M6x 16
Plain washer: 6.4x12x1.6
11 Lift the parallel rod up into position for fitting
of the upper end.
xx1100000163
12 Refit the upper end of the parallel rod in the

same way.
13
DANGER


4 Repair
4.4.9 Replacing the complete lower arm system
Location of lower arm system

The complete lower arm system consist of lower arm and parallel arm. The lower
arm system is located as shown in the figure.
xx1100000175
A Lower arm
B Parallel arm
Required equipment

Lower arm For art. no. see:
Lock screw - M16x90

4 Repair
Continued

Rotation tool
below.
Circuit diagram See Circuit diagrams on
page 399.

Action Note
calibration:
Removing the lower arm system

Use this procedure to remove the lower arm system.
Action Note

4 Repair
Continued
Action Note
2
DANGER
Turn off all:

ing area.
3 Secure the lower arm with a lock screw

M16x90 in the hole as shown in the figure.
xx1000001179
4 Remove the linkage starting with upper link See sections:

arm. • Replacing linkage - upper link arm
on page 233
on page 241
page 248
5 Remove the parallel rod. See section Replacing parallel rod on
page 265.
6 Remove the cable harness in upper and lower See sections:
arms. • Replacing cable harness, lower
Secure the cable harness in a way that it is end (axes 1-3) on page 144
protected from getting damaged and from oil • Replacing the cable harness, upper
spill. end (incl. axis 6) on page 154
7 Remove the complete upper arm. See section Replacing the upper arm on
page 216.
8 Remove the cover on motors axes 2-3 and See section Replacing motors, axes 2 and
disconnect the motor cables. 3 on page 300.
Motors are removed in order to be able to
rotate lower and parallel arms.

4 Repair
Continued
Action Note
9
CAUTION
The robot lower arm weighs 110 kg.

accordingly!
10 Secure the complete lower arm system with

a roundsling in an overhead crane or similar.
xx1100000179
11 Remove the lock screw securing the lower

arm system.
xx1000001179
12 In order to release the brake, connect the Connect to connector R2.MP2 or R2.MP3
24VDC power supply. depending on which side:
• + : pin 2
• -: pin 5

4 Repair
Continued
Action Note
13 Remove all attachment screws (M12) secur-
ing the lower arm system, on both sides.
xx0200000165
A: Rotation tool
Note
The lower and parallel arms need to be ro-

tated in order to reach all attachment screws. xx1100000180
Release the brake and use a rotation tool fit-
ted to the motor axis.
14 Remove the two screws, and remove the

sealing cover.
xx1100000181
15 The space between gearboxes is cramp.

Therefore push the lower and parallel arms Note
together with the help of an iron bar or similar
before removing them. If the parts are not pushed together, it will
be difficult to remove the complete lower
arm.

4 Repair
Continued
Action Note
16
DANGER
Before removing the lower arm system the

parallel arm must be secured to the lower
arm. If not secured the parallel arm can fall
down and cause a serious accident!
xx1100000182
17 Move the parallel arm and secure it to the

lower arm as shown in the figure, to prevent
it from falling down.
xx1100000178

4 Repair
Continued
Action Note
18 Remove the complete lower arm system.
xx1100000183
19 How to remove the parallel arm is described

in section Replacing the parallel arm on
page 285.
Refitting the lower arm system

Use this procedure to refit the lower arm system.
Action Note
1 Fit the parallel arm to the lower arm. See section
• Replacing the parallel arm on
page 285
2
CAUTION

accordingly!

4 Repair
Continued
Action Note
3 Fit a roundsling, to the lower arm system and
lift it up.
DANGER
Secure the parallel arm to the lower arm be-

fore lifting the lower arm system. If not se-
cured, the parallel arm can fall down and
cause a serious accident!
xx1100000184
4 In order to release the brake, connect the Connect to connector R2.MP2 or R2.MP3
24VDC power supply. depending on which side:
• + : pin 2
• -: pin 5
5 Place the lower arm system in its mounting For art. no. see:
position. • Required equipment on page 275
If the hole pattern need to be adjusted, re-
lease the brake and use a rotation tool to
find the correct hole pattern by moving the
gears.
xx0200000165
A: Rotation tool
xx1100000185
6
Note
Refit the axis 2 side first!

4 Repair
Continued
Action Note
7 Refit all M12 attachment screws with washers Tightening torque M12: 120 Nm
on the axis 2 side that are possible to fit at
this stage.
xx1100000180
8 Push the parallel arm against the axis 3 side

with the help of an iron bar or similar.
9 Refit all M12 attachment screws with washers Tightening torque M12: 120 Nm
on the axis 3 side that are possible to fit. See
figure above!
10 Change the position of the lower arm in order
to reach the remaining attachment holes, and
fit the remaining screws.
11 Secure the lower arm by fitting a lock screw
M16x90.
xx1000001179

4 Repair
Continued
Action Note
12 Refit the sealing cover, and secure with the
two screws.
xx1100000181
13 Reconnect the motor cables axes 2-3 and See section Replacing motors, axes 2 and
refit the cover. 3 on page 300.
14 Refit the complete upper arm. See section Replacing the upper arm on
page 216.
15 Refit the cable harness in the upper arm and See Replacing the cable harness, upper
lower arms. end (incl. axis 6) on page 154 and Repla-
cing cable harness, lower end (axes 1-3)
on page 144.
16 Refit the parallel rod. See section Replacing parallel rod on
page 265
17 Refit the linkage starting with the link. See sections:
page 248
on page 241
on page 233
18 Remove the lock screw.
page 363.
20
DANGER


4 Repair
4.4.10 Replacing the parallel arm
Location of parallel arm

The parallel arm is located as shown in the figure.
xx1100000176
A Lower arm
B Parallel arm
Required equipment

Parallel arm For spare part no. see:

4 Repair
Continued

Press equipment 3HAC076749-001 For replacing the bearings on
parallel arm.
User instructions are en-
below.

Action Note
calibration:
Removing the parallel arm

Use this procedure to remove the parallel arm.
Action Note
2 Remove the complete lower arm system from See section Replacing the complete lower
the robot. arm system on page 275.

4 Repair
Continued
Action Note
3
DANGER
Turn off all:

ing area.
4
DANGER
Secure the parallel arm to the lower arm be-

fore lifting the lower arm system. If not se-
cured, the parallel arm can fall down and
cause a serious accident!
xx1100000182
5
CAUTION

accordingly!

4 Repair
Continued
Action Note
6 Secure the lower arm system as shown in
the figure.
xx1100000184
7 Put the lower arm system on a workbench as

shown in the figure.
Tip
Removal of the parallel arm is best perfomed

on a workbench.
xx1100000186
8
CAUTION
The parallel arm system weighs 40 kg.

accordingly!
9 Secure the parallel arm with a roundsling in

an overhead crane.

4 Repair
Continued
Action Note
10 Remove the parallel arm from the lower arm
by lifting it straight up.
Tip
If needed use a plastic mallet and hit the

parallel arm from inside.
xx1100000187
11 Turn the parallel arm over and put it on a

workbench or similar, as shown in the figure.
xx1100000189
12 If needed, replace bearings, using the press

equipment, parallel arm, according to user
instructions enclosed with the equipment.
xx1100000218
xx0900000813

press tool.
DANGER
Handling the tool incorrectly will cause seri-

ous injury.
Read and follow enclosed user instructions
for the tool.

4 Repair
Continued
Refitting the parallel arm

Use this procedure to refit the parallel arm.
Action Note
1 Refitting the parallel arm is best performed
on a workbench.
2 Check that the assembly and the condition
of the bearing is good.
3 Check that the lower arm is placed on the
workbench as shown in the figure with the
hole for the bearing pointing up.
xx1100000193
4 Apply some grease in the hole for the bear- Art. no. is specified in Required equip-
ing. ment on page 285
xx1100000192

4 Repair
Continued
Action Note
5
CAUTION
The parallel arm system weighs 40 kg.

accordingly!
6 Lift the parallel arm to where the lower arm

is placed.
7 Push the parallel arm with bearing fitted, onto
the lower arm.
Tip
Use a plastic mallet if needed. Knock on the

casting surface of the parallel arm.
xx1100000194
8 Refit the sealing cover, and secure with two

screws.
xx1400000070
9 Refit the complete lower arm system. See section Replacing the complete lower
arm system on page 275.
page 363.

4 Repair
Continued
Action Note
11
DANGER


4 Repair
4.5.1 Replacing motor, axis 1
4.5 Motors
Location of motor axis 1

The motor axis 1 is located on the left hand side of the robot as shown in the figure.
Required equipment

Motor axis 1 For spare part number, Includes:
see: • motor
• Spare parts on • pinion
page 397
• o-ring (The old o-ring must be
replaced when replacing the
motor)

4 Repair
Continued

Screw - M12x100 fully, threaded
For lubricating the o-ring.
Bits extension 3HAC12342-1 Used to reach the attachment
screws for the motor.
Power supply - 24 VDC, max. 1,5 A
Standard toolkit - Content is defined in section Stand-
Other tools and proced- These procedures include refer-
ures in the step-by-step
instructions below.
Circuit diagram See chapter Circuit diagrams on
page 399.

Action Note
calibration:

4 Repair
Continued
Removing motor axis 1

Use this procedure to remove motor axis 1.
Action Note
repair procedure.
2
DANGER
Turn off all:

area.
3 Remove the motor cover to get access to the

connectors on top of the motor.
4 Remove the cable gland cover at the cable exit

of the motor.
Note
Make sure the gasket is undamaged! Replace

if damaged.

4 Repair
Continued
Action Note
5 Disconnect all connectors beneath the motor
cover.
6 In order to release the brake, connect the 24 Connect to connector R2.MP1
VDC power supply. • + : pin 2
• -: pin 5
7 Remove the attachment screws of the motor.
Use the bits extension.
8 If required, press the motor out of position by Always use removal screws and tools
fitting two screws in the holes on the motor for in pairs!
pressing out the motor. M12x100, fully threaded
9
CAUTION
The motor weighs 29 kg.

cordingly!

4 Repair
Continued
Action Note
10 Remove the motor by carefully lifting it straight
up to get the pinion away from gear.
CAUTION
Be careful not to damage the pinion in the pro-

cess!
11 Disconnect the brake release voltage.

12 Check the pinion. If there is any damage, the
pinion must be replaced.
Refitting motor axis 1

Use this procedure to refit motor axis 1.
Action Note
1 Make sure the o-ring on the circumference of
the motor is seated properly. Lightly lubricate
the o-ring with grease.
Parts:
A Circumference of motor
B O-ring
Note
The o-ring must be replaced when re-

placing the motor.

4 Repair
Continued
Action Note
2
CAUTION

cordingly!

• -: pin 5
4 Gently lower the motor into the gear, making
sure the pinion is properly mated to the gearbox
of axis 1.
Note
Make sure the motor is turned the right way.

See figure.
Note
Make sure the motor pinion does not get dam-

aged!
5 Secure the motor with its four attachment

screws and plain washers. Use the bits exten-
sion.
Attachment screws:
• M10x40 quality 12.9 Gleitmo
Tightening torque:
• 50 Nm
7 Reconnect all connectors beneath the motor
cover.

4 Repair
Continued
Action Note
8 Refit the cable gland cover at the cable exit with
Note

Replace gasket if damaged.
9 Refit the motor cover with its attachment

screws.
Note

tools.
page 363.
page 353.
11
DANGER


4 Repair
4.5.2 Replacing motors, axes 2 and 3
Location of motors, axes 2 and 3

The motors axes 2 and 3 are located on either side of the robot as shown in the
figure.
The procedure is the same for both motors.
xx1000001174
Required equipment

Motor axes 2-3 For spare part no. see: Includes
• Spare parts on • motor
page 397 chapter • pinion
• o-ring (the o-ring must be re-
placed when the motor is re-
placed)

4 Repair
Continued

Guide pins 3HAC13120-2 M10x150
For guiding the motor.
Guide pins are to be used in pairs!
Lifting accessory, motor 3HAC15534-1
axes 2-3
Lock screw - M16x90
For securing the lower arm.
Bits extension 3HAC12342-1 Used to reach the attachment
screws for the motor.
Power supply - 24 VDC, 1.5 A
Rotation tool Used to rotate the motor pinion
when mating it to the gear, when
brakes are released with 24 VDC
power supply.
Other tools and procedures These procedures include refer-
may be required. See references to the tools required.
tions below.
page 399.

Action Note

4 Repair
Continued
Action Note
calibration:
Removing motors axes 2 and 3

Use this procedure to remove motors axes 2 and 3.
Action Note
repair procedure.
2 Run the robot to a position close enough to its
calibration position, to allow the lock screw to
be inserted into the hole for lock screw.
xx1000001179
3 Lock the lower arm by inserting the lock screw See figure above.
into the hole of the frame.
This is done in order to secure axis 2 from col-
lapsing when the axis 2 motor is being removed.
CAUTION
Tighten by hand!

4 Repair
Continued
Action Note
4 Run axis 3 to the end position so that it rests
against the mechanical stop. Release the brake
of axis 3 in order to set the weight of axis 3
against the mechanical stop.
This is done in order to secure axis 3 from col-
lapsing when the axis 3 motor is being removed.
5
DANGER
Turn off all:

area.
6 Drain the oil from gearbox. See section

• Changing oil, gearbox axes 2
and 3 on page 122.
7 Remove the motor cover.
xx1000001182

4 Repair
Continued
Action Note
8 Remove the cable gland cover at the cable exit
.
Note
Make sure the gasket is not damaged! Replace

if damaged.
xx1000001183
9 Disconnect all connectors beneath the motor

cover.
• -: pin 5
11 Unscrew attachment screws and washers of
the motor. Use the bits extension.
xx1000001181

4 Repair
Continued
Action Note
12 Fit two guide pins in two of the motors attach- Art. no. is specified in Required
ment holes. equipment on page 300.
The figure shows IRB 760 but the
xx1000001131
13 If required, press the motor out of position by M12x70, fully threaded.

fitting two screws in the remaining attachment Always use the removal screws and
holes of the motor, diagonal to each other. tools in pairs!
xx1000001184
14 Remove the two screws and fit the lifting tool, Art. no. is specified in Required
motor axes 2-3 to the motor. equipment on page 300.
15
CAUTION

cordingly!

4 Repair
Continued
Action Note
16 Pull out the motor on the guide pins to get the The figure shows IRB 760 but the
pinion away from the gear. principle is the same.
Make sure the pinion does not get damaged!
xx1000001105
17 Remove the motor by gently lifting it straight

out and place it on a secure surface.
18 Disconnect the brake release voltage!
19 Check the pinion. If there is any damage, the
motor pinion must be replaced.

4 Repair
Continued
Refitting, motors axes 2 and 3

Use this procedure to refit motors axes 2 and 3.
Action Note
xx1000001186
Parts:
• B: O-ring
• C: Circumference
• -: pin 5
3 Fit the lifting tool, motor axes 2-3 to the motor. Art. no. is specified in Required
4 Fit the two guide pins in the two lower motor Art. no. is specified in Required
attachment holes. equipment on page 300.
The figure shows IRB 760 but the
xx1000001131

4 Repair
Continued
Action Note
5
CAUTION

cordingly!
6 Lift the motor and guide it on to the guide pins, The figure shows IRB 760 but the
as close to the correct position as possible principle is the same.
without pushing the motor pinion into the gear.
Note
Make sure the motor is turned the right way,

that is connections for the cables facing down-
wards.
xx1000001185
7 Remove the lifting tool and allow the motor to

rest on the guide pins.
8 Use the rotation tool in order to rotate the motor
pinion when mating it to the gear (see figure).
Fit the motor, making sure the motor pinion is
properly mated to the gear of gearbox axis 2-3
and that it doesn´t get damaged.
Note
The rotation tool is used beneath the motor

cover, directly on the motor shaft as shown in
figure above.
xx0200000165
Part:
Rotation tool
9 Remove the guide pins.

4 Repair
Continued
Action Note
screws and plain washers. Use the bits exten-
sion.
Reused screws can be used, providing they are
lubricated as detailed in section Screw joints
on page 387 before fitting.
xx1000001181
Attachment screws:
• M10 x 40 quality 12.9 Gleitmo
Tightening torque:
• 50 Nm
12 Reconnect all connectors beneath the motor Connect in accordance with markings
cover. on connectors.
13 Refit the cable gland cover at the cable exit with
its two attachment screws.
Note
Use a new gasket!
xx1000001183

4 Repair
Continued
Action Note
14 Refit the motor cover with its attachment screws
and washers.
Note
xx1000001182
15 Remove the lock screw from the hole for lock

screw.
xx1000001179
16 Perform a leak-down test of the axis 2 or 3 See section Performing a leak-down

gearbox. test on page 136.
17 Refill the gearbox with oil. See section Changing oil, gearbox
axes 2 and 3 on page 122.
tools.
page 363.
page 353.

4 Repair
Continued
Action Note
19
DANGER


4 Repair
Location of motor axis 6

Motor axis 6 is located in the center of the tilthouse as shown in the figure.
xx1100000090
Required equipment

Motor axis 6 For spare part no. see: Includes
• Spare parts on • motor
page 397 • pinion
• o-ring (the o-ring must be
replaced when the motor is
replaced)
Bits extension 3HAC12342-1 Used to reach attachment screws
for motor.

4 Repair
Continued

Power supply - 24 VDC, 1.5 A
tions below.
page 399.

Action Note
calibration:
Removing, motor axis 6

Use this procedure to remove motor, axis 6.
Action Information

4 Repair
Continued
Action Information
2 Run the robot to a position where it is easi-
est to remove the motor axis 6 when stand-
ing in front of the robot.
Note
The motor axis 6 can be replaced without

draining the gear oil.
3
DANGER
Turn off all:

working area.
4 Remove motor cover.
xx1000001223
5 Remove the cable gland cover at the cable

exit by unscrewing its attachment screw (A)
on the inside.
Note
xx0600002694

4 Repair
Continued
Action Information
A
6 Disconnect all connectors beneath the
cover.
B
Note
The connection to the UL lamp, must also

be disconnected, if the robot is equipped
with one.
C
xx1000001287
A Signal lamp
B Attachment screw M6x8 (2 pcs)
C Motor cover
7 In order to release the brake, connect the Connect to connector R2.MP6
24 VDC power supply. • + : pin 2
• -: pin 5
8 Remove attachment screws and washers.
Use the bits extension.
xx1000001225
9 If required, press the motor out of position Always use the screws for removal in
by fitting two screws in the motor attach- pairs!
ment holes diagonal to each other

4 Repair
Continued
Action Information
10 Lift the motor carefully to get the pinion
away from the gear.
Note
Make sure the pinion does not get dam-

aged!
xx1000001226

12 Remove the motor by gently lifting it straight
up and place it on a secure surface.
Refitting, motor axis 6

Use this procedure to refit motor axis 6.
Action Information
Note
The o-ring must be replaced when the motor is

replaced.
xx1000001109
Parts:
• A: Pinion
• B: O-ring
• C: Circumference

4 Repair
Continued
Action Information
• -: pin 5
3 Fit the two guide pins in two of the motor attach- Art. no. is specified in Required
ment holes. equipment on page 312.
4 Lift the motor carefully in place.
Make sure the motor pinion is properly mated
to the gearbox, axis 6.
Note
Make sure the motor is turned the correct way.

See figure!
xx1000001228
5 Remove the guide pins.

6 Apply locking liquid (Loctite 243) on the attach-
ment screws.
screws and washers.
Reused screws may be used, providing they
are lubricated as detailed in section Screw joints
on page 387 before fitting.
xx1000001225
Washers:
• 8.4x16x1.6 quality Steel-A2F
Attachment screws:
• M10 x 40 quality 8.8-A2F
Tightening torque:
• 50 Nm
4 Repair
Continued
Action Information
9 Perform a leak-down test of the axis 6 gearbox. See section Performing a leak-down
test on page 136.
10 Reconnect all connectors in motor axis 6. Connect in accordance with markings
on connectors.
11 Refit the connections to the UL lamp, if the ro-
bot is equipped with one.
12 Check the gasket. If damaged, replace it.
xx1000001224
13 Refit the cable gland with its attachment screw.
xx0600002694
• A: Screw holding the cable

gland
Replace if damaged.

4 Repair
Continued
Action Information
14 Refit the cover, motor axis 6 with its attachment
screws and washers.
Note
xx1000001223
15 Re-calibrate the robot! Pendulum Calibration is described in

tools.
page 363.
page 353.
16
DANGER


4 Repair
4.6.1 Replacing the axis 1 gearbox
4.6 Gearboxes
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure.
xx1100000122
Required equipment

Gearbox For spare part no. see: Includes:
• Spare parts on • gearbox
page 397. • all o-rings and sealing rings
O-ring 3HAB3772-93 Replace if damaged!

4 Repair
Continued

O-ring 3HAB3772-97 3 pcs
Replace if damaged!
Oil seal For spare part no. see: Replace if damaged!
• Spare parts on
page 397
Support, base and gear 1 3HAC15535-1
Adapter 3HAC040381-001
Lifting eye, M12 3HAC025333-005 2 pcs
Shackle Lifting capacity: 1,000 kg.
Lifting accessory (chain) 3HAC15556-1
Guide pins 3HAC022637-001 2 pcs, M12x130.
Used for guiding the gearbox into
place in the base.
Always use guide pins in pairs!
Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes op-
erating manual.
Required if Calibration Pendulum
is the valid calibration method for
the robot.
Calibration tool box, Axis 3HAC074119-001 Delivered as a set of calibration
Calibration tools.
Required if Axis Calibration is the
valid calibration method for the ro-
bot.
tions below.

Action Note

4 Repair
Continued
Action Note
calibration:
Removal, gearbox axis 1

Use this procedure to remove gearbox, axis 1.
Action Note
2 Move the robot to its most stable position,
shown in the figure to the right.
Jog the robot to this position:
Axis 2 = -40 degrees
Axis 3 = +65 degrees
3
DANGER
Turn off all:

working area.
4 Drain the axis 1 gearbox. See Changing oil, axis-1 gearbox on

page 118.
5 Remove the complete arm system. See Replacing the base, including axis 1
gearbox on page 180.
6 Unfasten the robot base from the foundation
by removing the base attachment screws.

4 Repair
Continued
Action Note
7 Fit two lifting eyes on each side of the The figure shows IRB 760 but is also valid
gearbox. for IRB 460.
Attach the lifting accessory, base and gear
1 and a roundsling, to the gearbox and
base.
xx1000001395
Specified in Required equipment on

page 320.
8
CAUTION
The base and axis 1 gearbox weighs 130

kg + 108 kg.
accordingly!
9 Lift the robot base including the axis 1 Art. no. is specified in Required equip-
gearbox to allow the base and gear 1 sup- ment on page 320.
port be fitted on each sides of the base.
10 Secure the support to the base and to the The figure shows IRB 760 but is also valid
foundation. for IRB 460.
Make sure the base remains in a stable
position before performing any work under-
neath the base!
xx1000000364
A Support base (4 pcs)

4 Repair
Continued
Action Note
11 Remove the bottom plate from underneath
the base in order to get access to the attach-
ment screws.
12 Unscrew the attachment screws and re-
move the washers.
xx1100000207
Attachment screws: 12 pcs.

Washers: 12 pcs.
13 Remove the cable guide in the center of
gearbox 1 by unscrewing its attachment
screws.
xx1000001387
14
CAUTION
The gearbox weighs 108 kg.

accordingly!
15 Lift the gearbox away with the already

mounted lifting tools.

4 Repair
Continued
Action Note
16 Turn the gearbox, and remove the protec-
tion pipe by unscrewing two attachment
screws.
Note
Move the protective pipe over to the new

gearbox.
xx1400000786
Refitting, gearbox axis 1

Use this procedure to refit gearbox, axis 1.
Action Note
1 Fit the support, base and gear 1 to the base. Mounting of the support, base and gear
1 is detailed in section Removal, gear-
box axis 1 on page 322.
The figure shows IRB 760 but is also
valid for IRB 460.
xx1000000364
A Support base (4 pcs)

2 Make sure the o-ring is seated properly in its Art no. is specified in Required equip-
groove on the gearbox. Lightly lubricate the ment on page 320.
o-ring with grease.

4 Repair
Continued
Action Note
3 Fit two lifting eyes on each side of the gear- Specified in Required equipment on
box. page 320.
Attach the lifting accessory, base and gear 1
and a roundsling, to the gearbox.
xx1000001395
4 Fit two guide pins in two of the attachment Specified in Required equipment on
holes in the gearbox, parallel to each other. page 320.
5
CAUTION

cordingly!
6 Check the three o-rings. Replace if damaged!
xx1300000015
7 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs!
lower it carefully to its mounting position.

4 Repair
Continued
Action Note
8 Secure the gearbox with its attachment 12 pcs, M16x60 quality 12.9 Gleitmo
screws and washers. Tightening torque: 300 Nm
Reused screws may be used, providing
they are lubricated as detailed in sec-
tion Screw joints on page 387 before fit-
ting.
xx1100000207
9 Refit the cable guide in the center of gearbox The figure shows IRB 760 but is also
1 with its attachment screws. valid for IRB 460.
xx1000001393
10
CAUTION
The base and axis 1 gearbox weighs 130 kg

+ 108 kg.
cordingly!
11 Lift the robot base and gearbox 1 and remove

the base and gear support.
12 Secure the base to the mounting site. See Orienting and securing the robot
on page 64.

4 Repair
Continued
Action Note
13 Refit the complete arm system. See Replacing the base, including axis
1 gearbox on page 180.
CAUTION
This is a complex task to be performed with

utmost care in order to avoid injury or dam-
age!
14 Perform a leak-down test. See section Performing a leak-down

test on page 136.
15 Refill the gearbox with oil. See Changing oil, axis-1 gearbox on
page 118.
lum, enclosed with the calibration tools.
page 363.
page 353.
17
DANGER


4 Repair
Location of the axis 2 gearbox

The axis 2 and 3 gearboxes are located on either side of the frame as shown in
the figure.
xx1100000123
Required equipment
Equipment, etc. Art.no Note

Gearbox, axis 2 or axis 3 For spare part no. see:
Lock screw M16x90 -
Screw M12x60 Fully threaded
Bits extension -

4 Repair
Continued

Guide pins - M12
Always use guide pins in
pairs.
Guide pins - M12 Length: 150 mm (the
longer one)
One shorter than the other.
pairs.
Pinion crank - Used to move the gearbox.
Lifting tool 3HAC025214-001 For lifting gearbox.
Includes lifting instruction art.
no. 3HAC025523-001.
below.

Action Note
calibration:

4 Repair
Continued
Preparations before removing the axis 2 gearbox

Use this procedure to do the necessary preparations before removing the axis 2
gearbox.
Note
Do not replace both gearboxes at the same time, unless the complete arm system
is already removed!
Action Note
2 Drain the gearbox from oil. Also see
Note
Time-consuming activity!
3 Jog axis 2 to 0 degrees and axis 3 to max +

degrees.
4 Insert the lock screw in the lower arm in order Dimension of the lock screw is speficied
to secure axis 2. in Required equipment on page 329.
NOTE!
Perform this by hand only!
xx1000001179
5 Release the brakes on axes 2 and 3 in order

to let the parallel arm rest on the damper.
6 Apply a roundsling (or similar) securing the
parallel rod to the lower arm. This is done in
order to lock the parallel arm in position.

4 Repair
Continued
Action Note
7
DANGER
Turn off all electric power, hydraulic and

pneumatic pressure supplies to the robot!
Removing the axis 2 gearbox

Use this procedure to remove the axis 2 gearbox.
Action Note
1 Remove the axis 2 motor. See Replacing motors, axes 2 and 3 on
Protect the cables from getting damaged and page 300.
from getting contaminated with oil spill.
2 Unscrew the attachment screws of the motor
flange and lift away the washers and the
motor flange.
xx1100000219
3 Apply two guide pins into two opposite holes

in the gearbox.
xx1100000220
Note
4
CAUTION

accordingly!
5 Fit the lifting tool to the gearbox. Art. no. is specified in Required equip-
ment on page 329.

4 Repair
Continued
Action Note
6 Unscrew the M12 attachment screws secur-
ing the gearbox to the lower arm system.
xx1100000221
7 If required, apply two fully threaded M12x60

screws to the holes in the gearbox, in order
to press it free.
8 Lift out the axis 2 gearbox using an overhead
crane or similar, with guidance from the fitted
guide pins.
Preparations before refitting the axis 2 gearbox

gearbox.
Action Note
1 Clean all contact surfaces from residuals of
paint and contamination.
2 Make sure that the o-ring is fitted to the
gearbox.
xx1100000223
3 Lightly lubricate the o-ring with grease.

4 Apply some grease on all contact surfaces.
4 Repair
Continued
Action Note
5 Fit two guide pins in opposite holes for the
gearbox, in the frame.
xx1100000224
6 Fit two guide pins in opposite holes of the NOTE!

gearbox. The position of the guide pins must be in
One of the guide pins shorter than the other a way that they are possible to be re-
in order to fascilitate fitting into the lower arm. moved later.
Refitting, the axis 2 gearbox

Use this procedure to refit the axis 2 gearbox.
Action Note
1
CAUTION

accordingly!
ment on page 329.
3 Use an overhead crane or similar and lift the
gearbox on to the guide pins.
4 Slide the gearbox carefully on the guide pins
to its mounting position.
5 Use a crank to move the gearbox in order to
find the holes for the attachment screws.
6 Secure the gearbox and the motor flange to
the frame with the attachment screws and
washers.
xx1100000219
Attachment screws: M12x60 quality 12.9

gleitmo (16 pcs)

4 Repair
Continued
Action Note
7 Remove the guide pins and replace them with
the remaining attachment screws.
8 Secure the gearbox to the lower arm system
with the attachment screws and washers.
xx1100000221

gleitmo (21 pcs)
9 Remove guide pins in the lower arm.
10 Secure the rest of the attachment screws. Tightening torque: 120 Nm
Concluding refitting procedure of the axis 2 gearbox

Use this procedure for the concluding refitting of the axis 2 gearbox.
Action Note
1 Wipe the gearbox clean from residual grease.
2 Refit the motor. See Replacing motors, axes 2 and 3 on
page 300.
3 Perform a leakdown test. See Performing a leak-down test on
page 136.
4 Refill the gearbox with oil. Draining, axes 2 and 3 on page 124

4 Repair
Continued
Action Note
5 Remove the lock screw, lower arm.
xx1000001179

page 363.
7
DANGER


4 Repair
Location of the axis 3 gearbox

The axis 2 and 3 gearboxes are located on either side of the frame as shown in
the figure.
xx1100000123
Required equipment

Gearbox, axis 2 or axis 3 For spare part no. see:
Lock screw M16x90 -
Screw M12x60 Fully threaded.
Bits extension -

4 Repair
Continued

Guide pins - M12
pairs.
Guide pins - M12 Length: 150 mm (the
longer one)
One shorter than the other.
pairs.
Pinion crank - Used to move the gearbox.
Lifting tool 3HAC025214-001 For lifting gearbox.
Includes lifting instruction art.
no. 3HAC025523-001.
below.

Action Note
calibration:

4 Repair
Continued
Preparations before removing the axis 3 gearbox

gearbox.
Note
Do not replace both gearboxes at the same time, unless the complete arm system
is already removed!
Action Note
2 Drain the gearbox from oil. Draining, axes 2 and 3 on page 124
Note
Time-consuming activity!
3 Jog axis 2 to 0 degrees and axis 3 to max +

degrees.
4 Release the brakes on axis 3 in order to let
the parallel arm rest on the damper.
5 Disassemble the lower end of the parallel rod See Replacing parallel rod on page 265.
(alternately remove the complete parallel
rod).
This is done in order to be able to move the
parallel arm in the continued removal pro-
cess.
6 Jog axis 3 (the parallel arm) to max - degrees.
7 Release the brakes on axis 3 in order to let
the parallel arm rest on the damper.
8 Jog axis 2 carefully to about +50 degrees.
NOTE! Check that the upper arm is moved
forwards during jogging.
9 Let the tilthouse rest against something rigid
that can take the weight of the upper arm.
Removing the axis 3 gearbox

Use this procedure to remove the axis 3 gearbox.
Action Note
1 Unscrew as many attachment screws that is
possible to remove in the parallel arm at this
point.
2 Jog axis 3 (the parallel arm) to max + de-
grees.
3
DANGER
Turn off all electric power, hydraulic and

pneumatic pressure supplies to the robot!

4 Repair
Continued
Action Note
4 Unscrew the remaining attachment screws
in the parallel arm.
5 Remove the axis 3 motor. See Replacing motors, axes 2 and 3 on
page 300.
6 Unscrew the attachment screws of the motor
flange and lift away the washers and the
motor flange.
xx1100000219
7 Apply two guide pins in opposite holes of the

gearbox.
xx1100000220
Note
8
CAUTION

accordingly!
9 Fit the lifting tool to the gearbox.

10 If required, apply two fully threaded M12x60
screws to the holes in the gearbox, in order
to press it free.
11 Lift out the gearbox from the frame using an
overhead crane or similar, with guidance from
the fitted guide pins.

4 Repair
Continued
Preparations before refitting the axis 3 gearbox

gearbox.
Action Note
1 Clean all contact surfaces from residuals of
paint and contamination.
2 Make sure that the o-ring is fitted to the
gearbox.
xx1100000223
3 Lightly lubricate the o-ring with grease.

4 Apply some grease on all contact surfaces.
5 Apply two guide pins in opposite holes for
the gearbox, in the frame.
xx1100000224
6 Apply two guide pins in opposite holes of the NOTE!

gearbox. The position of the guide pins must be in
One of the guide pins shorter than the other a way that they are possible to be re-
in order to fascilitate fitting into the lower arm. moved later.
7
CAUTION

accordingly!
ment on page 329.

4 Repair
Continued
Refitting the axis 3 gearbox

Use this procedure to refit the axis 3 gearbox.
Action Note
1 Slide the gearbox carefully on the guide pins
to its mounting position, using an overhead
crane (or similar)..
2 Use a crank to move the gearbox in order to
find the holes for the attachment screws.
3 Secure the gearbox and the motor flange to
the frame with the attachment screws and
washers.
xx1100000219

gleitmo (16 pcs)
4 Remove the guide pins and replace them with
the remaining attachment screws.
5 Secure as many attachment screws that is Attachment screws: M12x40 quality 12.9
possible to fit in this position, in the parallel gleitmo (21 pcs)
arm and secure the axis 3 gearbox. Tightening torque: 120 Nm
6 Refit the axis 3 motor. See Replacing motors, axes 2 and 3 on
page 300.
7 Jog axes 2 and 3 to a position where the re- Tightening torque: 120 Nm
maining attachment screws can be fitted and
secured.
8 Jog axis 3 (the parallel arm) very carefully to
the position where the parallel rod can be
refitted to the parallel arm.
9 Refit the parallel rod. See Replacing parallel rod on page 265.
10 Perform a leakdown test. See Performing a leak-down test on
page 136.
11 Refill the gearbox with oil. Draining, axes 2 and 3 on page 124
page 363.

4 Repair
Continued
Action Note
13
DANGER


4 Repair
4.6.4 Replacing gearbox axis 6
Location of gearbox axis 6

The axis 6 gearbox is located in the center of the wrist as shown in the figure.
xx1100000124
Required equipment

Gearbox axis 6 For spare part no. see: Includes o-ring
• Spare parts on
page 397.
Turning disk For spare part no. see:
• Spare parts on
page 397.

4 Repair
Continued

Washers 3HAA1001-172 Not included in gearbox.
Replace only if damaged!
O-ring 3HAB3772-58
164.7x3.53 3HAB3772-57 Must be replaced when reas-
sembling gearbox.
sembling gearbox.
sembling gearbox.
Used to lubricate the o-ring
Guide pins - Always use guide pins in
pairs!
Standard toolkit The content is defined in the
section Standard tools on
page 391.
Other tools and propcedures These procedures include
may be rquired. See refer- references to the tools re-
below.

Action Note
calibration:

4 Repair
Continued
Removing gearbox axis 6

Use this procedure to remove gearbox axis 6.
Action Note
2 Jog the robot to a position where the tilt-
house unit is placed in an appropriate ser-
vice position.
3
DANGER
Turn off all:

working area.
4 Drain the oil from the gearbox. See section

page 126
5 Remove the turning disk. See section
• Replacing the turning disk on
page 189
6 Remove the calibration plate axis 6.
xx1100000239

4 Repair
Continued
Action Note
7 Remove the gearbox by unscrewing the at-
tachment screws and washers that secure
it.
xx1100000229
8 If required apply two M8 screws in the holes

shown in the figure, and press out the
gearbox.
xx0200000220
9 Remove gearbox axis 6 carefully without

damaging pinion or gear.
xx1000001412

4 Repair
Continued
Action Note
10 Check the pinion. A damaged pinion must
be replaced!
xx1100000240
Refitting gearbox axis 6

Use this procedure to refit gearbox axis 6.
Action Note
1
DANGER
Turn off all:

working area.
2 Make sure the o-ring is undamaged and fit- For art. no. see: Required equipment on
ted to the gearbox. If the o-ring is damaged, page 344.
replace!
Lubricate the o-ring with grease.
xx1100000241
3 Release the brakes of the axis 6 motor See section

manually. • Manually releasing the brakes on
page 56

4 Repair
Continued
Action Note
4 Check that the pinion is undamaged on the
axis 6 motor.
xx1100000240
5 Carefully insert the axis 6 gearbox into the

tilthouse, using guide pins.
Make sure the gears of the gearbox mate
with the pinion of the axis 6 motor.
CAUTION
Do not damage pinion or gears in the pro-

cess!
xx1100000242

4 Repair
Continued
Action Note
6 Secure the gearbox with its attachment
screws and washers.
Reused screws may be used, providing they
are lubricated as detailed in section Screw
joints on page 387 before fitting.
xx1100000229
M8x40 quality 12.9 Gleitmo (8 pcs)

7 Refit the turning disk. See section
• Replacing the turning disk on
page 189
8 Perform a leak-down test. See section
• See section Performing a leak-
down test on page 136.
9 Refill the gearbox with oil. See section
page 126
10 Refit the calibration plate.
xx1100000239
11 Re-calibrate the robot. Pendulum Calibration is described in Op-

erating manual - Calibration Pendulum,
Axis Calibration is described in Calibrating
with Axis Calibration method on page 363.

4 Repair
Continued
Action Note
12
DANGER


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 363.
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.
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).
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 460. 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
with Axis Calibration method on page 363.
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
References
Article numbers for the calibration tools are listed in the section Special tools on
page 392.
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.
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 359. This will occur when:
• The battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are
connected at the first installation.
The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot
is changed, it needs to be re-calibrated for new resolver values.

5 Calibration
5.2.1 Synchronization marks and synchronization position for axes
5.2 Synchronization marks and axis movement directions
5.2.1 Synchronization marks and synchronization position for axes
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
Synchronization marks, IRB 460
xx1000001433
A Calibration plate, axis 1

B Calibration mark, axis 2
C Calibration mark, axis 3
D Calibration plate and marking, 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, 4 axes

Note! The graphic shows an IRB 260. The positive direction is the same for all
4-axis robots
xx0500001927

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.
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 357.
3 When all axes are positioned, update the Step 2 - Updating the revolution counter
revolution counter. with the FlexPendant on page 360.
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 460 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).

5 Calibration
Continued
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
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943

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

5 Calibration
Continued
Action
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 377.

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

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

The 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.
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.

5 Calibration
Continued
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 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.

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.
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.
xx1700000437
xx1700000438

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
pin covers and protective plugs
for the bushing.

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.
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
pin covers and protective plugs
for the bushing.
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 364.
2 Choose which axis/axes to calibrate.
3 The robot moves to synchronization position.
4 Validate the synchronization marks.
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.

5 Calibration
Continued
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.
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.
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.
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 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 370.

5 Calibration
Continued
Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished,
the RobotWare program needs to be started again. Use this procedure to take
required action.
Situation Action
The three-position enabling device on the Press and hold the three-position enabling
FlexPendant has been released during robot device and press Play.
movement.
The RobotWare program is terminated with Remove the calibration tool, if it is installed,
PP to Main. and restart the calibration procedure from
the beginning. See Starting the calibration
procedure.
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 358
After calibration
Action Note
1 Check the o-ring on the fixed calibration pin.
Replace if damaged or missing.
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.
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.

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 silver label (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.
12 (For system containing SafeMove or EPS) Synchronize SafeMove to activate
SafeMove.
13 Perform test run.
14 Update the label for resolver values with new 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 373).
Example "Adjust axis 4":
1 Create a backup.

5 Calibration
Continued
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 Verifying the calibration
5.6 Verifying the calibration
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
Verifying the calibration

Use this procedure to verify the calibration result.
Action Note
1 Run the calibration home position program twice. See Checking the synchron-
Do not change the position of the robot axes after running ization position on page 377.
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 357.
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
5.7 Checking the synchronization position
5.7 Checking the synchronization position
Introduction
Check the synchronization position of the robot before beginning any programming
of the robot system. This may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the FlexPendant.
Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their
synchronization position.
Action Note
1 On ABB menu tap Program editor.
2 Create a new program.
3 Use MoveAbsJ in the Motion&Proc menu.
4 Create the following program:
MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, fine, tool0
5 Run the program in manual mode.

6 Check that the synchronization marks for the axes See Synchronization marks and
align correctly. If they do not, update the revolu- synchronization position for axes on
tion counters. page 357 and Updating revolution
counters on page 359.
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 357 and
date the revolution counters. Updating revolution counters on page 359.

6 Decommissioning
6.1 Environmental information
6 Decommissioning
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
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Aluminium Covers, synchronization brackets

Batteries, Lithium Serial measurement board
Cast iron/nodular iron Base, lower arm, upper arm
Copper Cables, motors
Neodymium Brakes, motors
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
6.2 Scrapping of robot
6.2 Scrapping of robot
Important when scrapping the robot
DANGER
When a robot is disassembled while being scrapped, it is very important to

remember the following before disassembling starts, in order to prevent injuries:
• Always remove all batteries. If a battery is exposed to heat, for example
from a blow torch, it will explode.
• Always remove all oil/grease in gearboxes. If exposed to heat, for example
from a blow torch, the oil/grease will catch fire.
• When motors are removed from the robot, the robot will collapse if it is not
properly supported before the motor is removed.

7 Reference information
7.1 Introduction
7.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

7.2 Applicable standards
Note
The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.
General
The product is designed in accordance 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 deviations
from ISO 10218-1:2011, these are listed in the declaration of incorporation which
is part of the product delivery.
Normative standards as referred to from ISO 10218-1
Standard Description
ISO 9283:1998 Manipulating industrial robots - Performance criteria and related
test methods
ISO 10218-2 Robots and robotic devices - Safety requirements for industrial
robots - Part 2: Robot systems and integration
ISO 12100 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design
ISO 13850 Safety of machinery - Emergency stop - Principles for design
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
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
Other standards used in design
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
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 13732-1:2006 Ergonomics of the thermal environment - Part 1
IEC 60974-1:2012 i Arc welding equipment - Part 1: Welding power sources

Continued
IEC 60974-10:2014 i Arc welding equipment - Part 10: EMC requirements
ISO 14644-1:2015 ii Classification of air cleanliness
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots.
ii Only robots with protection Clean Room.

7.3 Unit conversion
7.3 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

7.4 Screw joints
7.4 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. Screws treated with Gleitmo may be reused 3-4 times before the coating
disappears. After this the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber
type should be used.
Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the
repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.
Lubricant Article number
Molycote 1000 (molybdenum disulphide grease) 3HAC042472-001
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.

7.4 Screw joints
Continued
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Note
A special torque specified in the repair, maintenance or installation procedure

overrides the standard torque.
Oil-lubricated screws with allen head screws

oil-lubricated screws with allen head screws.
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
M24 680 960 1150
Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Note

Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M8 28 35

7.4 Screw joints
Continued
Dimension Tightening torque (Nm) Tightening torque (Nm)

Class 10.9, lubricated i Class 12.9, lubricated i
M10 55 70
M12 96 120
M16 235 300
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent
Water and air connectors

water and air connectors when one or both connectors are made of brass.
Note

Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm -

Nominal Min. Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

7.5 Weight specifications
7.5 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.

7.6 Standard tools
7.6 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 Rem.

1 Ring-open-end spanner 8-19 mm
1 Socket head cap 5-17 mm
1 Torx socket no: 20-60
1 Box spanner set
1 Torque wrench 10-100 Nm
1 Torque wrench 75-400 Nm
1 Ratchet head for torque wrench 1/2
2 Hexagon-headed screw M10x100
1 Hexagon-headed screw M16x90
1 Hex bit socket head cap no. 14 socket 40 mm L=100 mm
1 Hex bit socket head cap no. 14 socket 40 mm L=20 mm To be shortened to 12 mm
1 Hex bit socket head cap no. 6 socket 40 mm L=145 mm
1 Hex bit socket head cap no. 6 socket 40mm bit L=220 mm
1 Multigrip plier
1 Plastic mallet

7.7 Special tools
7.7 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 391, and of special tools, listed directly in the instructions
and also gathered in this section.
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.
Description Art. no. Note
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.
Description Art. no. Note
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.
Special tools
This table specifies the special tools required during several of the service
procedures. The tools are specied directly in concerned instructions.
Description Qty Article no.
Guide pins M12x130 2 3HAC022637-001
Guide pins M10x150 2 3HAC13120-2

7.7 Special tools
Continued

Guide pins M10x140 1 -
(Used with one of the M10x150 guide pins
when replacing the axis 2 and 3 gear-
boxes)
Lifting eye M12 2 3HAC025333-005
Adapter 2 3HAC040381-001
(used with lifting eye M12)
Shackle, lifting capacity 1,000 kg 2 -
(Used with lifting eye M12)
Lifting eye bolt, M20 2 -
Shackle, lifting capacity 2,000 kg 2 -
(Used with lifting eye bolt M20)
Crank 1 -
Press tool, premounting outer race bear- 1 3HAC077982-001
ing
Press tool, replacing shaft tilthouse 1 3HAC040029-001
The tool consists of:
• 3HAC040029-002 Pressing tool
bearing
bearing
• 3HAC040021-005 Hollow cylinder
RCH 123
• 3HAC040022-004 Threaded bar
M16 length 450 mm (removal). For
refitting length 350 mm.
Auxiliary shaft 1 3HAC040035-001
Used together with press tool
3HAC040029-001 (only when removing).
KM7 socket 1 3HAC040025-001
Adapter 1 3HAC040027-001
Press tool, support ring 1 3HAC072616-001
Press tool, upper arm 1 3HAC040026-001
The tool is also used as Pull tool. Differ-
ence: Press bushing is used instead of
support bushing.
• 3HAC040026-003 Press bushing
upper arm
• 3HAC040021-004 Thread washer
RCH 123
M16 length 350 mm.

7.7 Special tools
Continued

Pull tool, upper arm 1 3HAC040026-001
The tool is also used as Press tool. Differ-
ence: Support bushing is used instead of
Press bushing.
• 3HAC040026-004 Support bush-
ing
upper arm
• 3HAC040021-004 Thread washer
RCH 123
M16 length 350 mm.
KM12 socket 1 3HAC040023-001
Auxiliary shaft 1 3HAC040022-002
Press tool link, bearing outer races 1 3HAC077981-001
Lower part of pressing tool 1 3HAC040031-001
Press tool, link 1 3HAC040022-001
RCH 123
M16 length 350 mm.
KM8 socket 1 3HAC040024-001
Mounting/Demounting tool 1 3HAC040021-001
(Parallel rod)
RCH 123
M16 length 530 mm.
Shims thickness 8 mm 1 -
Rotation tool 1 -
Screw M12x100 2 -
Fully threaded
Screw M12x60 2 -
Fully threaded
Bits extension 1 3HAC12342-1
Bits holder 1 -
Stahlwille 736/40 D10 (or similar)
Lifting accessory, motor axes 2-3 1 3HAC15534-1

7.7 Special tools
Continued

Support, base and gear ax 1 1 3HAC15535-1
Lifting accessory, base and gear ax 1 1 3HAC15556-1
Lifting accessory 1 3HAC025214-001
Oil collecting vessel capacity 8,000 ml 1 -
Oil exchange equipment 1 3HAC021745-001

7.8 Lifting accessories and lifting instructions
7.8 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.

8 Spare parts
8.1 Spare part lists and illustrations
8 Spare parts
8.1 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.

9 Circuit diagrams
9.1 Circuit diagrams
9 Circuit diagrams
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 Compact 3HAC049406-003
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 67, design 14 3HAC024120-005
Circuit diagram - Spot welding cabinet 3HAC057185-001
Manipulators

Circuit diagram - IRB 120 3HAC031408-003
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

9 Circuit diagrams
Continued

3HAC029940-001
Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005
3HAC025744-001
Circuit diagram - IRB 910SC 3HAC056159-002

Index
Index disposal, 379

changing oil
axis 1, 118
A axis 2, 122
additional mechanical stop location, 111
axis 3, 122
allergenic material, 28
axis 6, 126
aluminum
cleaning, 132
disposal, 379
climbing on robot, 32
ambient humidity
Cold environments, 86
operation, 42
connecting the robot and controller, cabling, 87
storage, 42
copper
ambient temperature
disposal, 379
operation, 42
storage, 42 D
assembly instructions, 39 damage to additional mechanical stop, 111
assessment of hazards and risks, 28 damage to mechanical stop, 109
Axis Calibration, 363 dampers, 113
calibration tool dimensions
article number, 366, 370 turning disk, 70
examining, 366 upper arm, 68
installation position, 368 direction of axes, 358
overview of method, 363
procedure on FlexPendant, 370 E
protective cover and protection plug, 368, 370 environmental information, 379
equipment on robot, 68
B ESD
base plate damage elimination, 47
guide pins, 59 sensitive equipment, 47
securing, 59 extra equipment
batteries robot, 68
disposal, 379 turning disk, 70
battery upper arm, 68
replacing, 128, 171
battery pack F
replacing, interval, 96 fire extinguishing, 29
battery shutdown fitting equipment on robot, 68
service routine, 128, 171 fitting fork lift, 48
brake release, 56 FlexPendant
brake release board, replacement, 176 jogging to calibration position, 377
brakes MoveAbsJ instruction, 377
testing function, 36 updating revolution counters, 360
buttons for brake release, 56 fork lift, 51
foundation
C requirements, 42
cabinet lock, 29
cable harness attachments, 105 G
cabling, robot, 87 gearbox
cabling between robot and controller, 87 oil change axis 1, 118
calibrating oil change axis 2, 122
robot, 363 oil change axis 3, 122
roughly, 359 oil change axis 6, 126
calibrating robot, 363, 375 gearbox axis 1, replacement, 320
calibration gearboxes
rough, 359 location of, 117
standard type, 354 grease, 32
verification, 376 disposal, 379
when to calibrate, 356 guide pins, base plate, 59
calibration manuals, 355
calibration marks, 357 H
Calibration Pendulum hanging
overview of method, 375 installed hanging, 28
calibration position hazard levels, 19
jogging to, 377 hazardous material, 379
scales, 357 height
calibration scales, 357 installed at a height, 28
carbon dioxide extinguisher, 29 hot surfaces, 32
cast iron HRA, 28

Index
humidity axis 1, 118

operation, 42 axis 2, 122
storage, 42 axis 3, 122
axis 6, 126
I oil level
information labels location, 107 gearbox axes 2-3, 100
inspecting gearbox axis-1, 98
additional mechanical stop, 111 gearbox axis 6, 103
cable harness, 105 operating conditions, 42
information labels, 107 option
mechanical stop, 109 signal lamp, 73
inspecting oil levels original spare parts, 17
axes 2-3, 100
axis-1, 98 P
axis 6, 103 pedestal
inspection installed on pedestal, 28
dampers, 113 personnel
installation requirements, 18
mechanical stop axis 1, 84 plastic
installing equipment on robot, 68 disposal, 379
instructions for assembly, 39 positive directions, axes, 358
integrator responsibility, 28 PPE, 18
intervals for maintenance, 95 product standards, 384
protection classes, 43
L protection type, 43
labels protective equipment, 18
robot, 21 protective wear, 18
leak-down test, 136
lifting accessory, 390 R
lifting robot recycling, 379
with fork lift, 51 regional regulations, 28
with roundslings, 54 release brakes, 35
limitation of liability, 17 replacement
linkage brake release board, 176
replacing lower rod, 241 gearbox axis 1, 320
replacing upper rod, 233 turning disk, 189
Lithium replacements, report, 135
disposal, 379 replacing
loads on foundation, 41 lower rod, linkage, 241
lock and tag, 29 upper rod, linkage, 233
lubricants, 32 xx, 90
lubrication report replacements, 135
amount in gearboxes, 117 requirements on foundation, 42
type of lubrication, 117 responsibility and validity, 17
restricting
M working range axis 1, 84
maintenance schedule, 95 revolution counters
manually releasing brakes, 56 storing on FlexPendant, 360
mechanical stop updating, 359
axis 1, 84 risk of burns, 32
mechanical stop location, 109 risk of tipping, 46
MoveAbsJ instruction, 377 robot
labels, 21
N protection class, 43
national regulations, 28 protection types, 43
negative directions, axes, 358 symbols, 21
neodymium rubber
disposal, 379 disposal, 379
nodular iron
disposal, 379 S
safety
O brake testing, 36
oil, 32 ESD, 47
amount in gearboxes, 117 fire extinguishing, 29
disposal, 379 release robot axes, 35
type of oil, 117 signals, 19
oil change signals in manual, 19

Index
symbols, 19 T
symbols on robot, 21 temperatures
safety devices, 29 operation, 42
safety equipment storage, 42
mechanical stop, 84 testing
signal lamp, 115 brakes, 36
safety hazard tools
hydraulic system, 30 Axis Calibration, 392
pneumatic system, 30 Calibration Pendulum, 392
safety signals for service, 392
in manual, 19 torques on foundation, 41
safety standards, 384 troubleshooting
scales on robot, 357 oil spills, 132
schedule for maintenance, 95 safety, 37
screw joints, 387 turning disk dimensions, 70
securing turning disk replacement, 189
base plate, 59
securing, robot, 64 U
securing the robot to foundation, attachment screws, 64 UL lamp, installation, 73
signal lamp, installation, 73 upcycling, 379
signals updating revolution counters, 359
safety, 19 upper arm
SMB dimensions, 68
replacing, 171 users
SMB battery requirements, 18
extension of lifetime, 128, 171
replacing, 128, 171 V
special tools, 392 validity and responsibility, 17
speed velocity
adjusting, 86 adjusting, 86
stability, 46 verifying calibration, 376
standards, 384
ANSI, 384 W
CAN, 384 weight, 40
EN IEC, 384 base plate, 58, 63
EN ISO, 384 robot, 53–54, 183, 186, 208, 211, 222, 226, 278, 281,
start of robot in cold environments, 86 287–288, 291, 296, 298, 305, 308, 323–324, 326–
steel 327, 332, 334, 340–341
disposal, 379 working range, 44
storage conditions, 42 restricting axis 1, 84
symbols X
safety, 19 xx
synchronization position, 359 replacing, 90
sync marks, 357
system integrator requirements, 28 Z
zero position
checking, 377

ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
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 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
3HAC039842-001, Rev U, en


3HAC039842 PM IRB 460-En

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© Copyright 2012-2021 ABB. All rights reserved.

© Copyright 2012-2021 ABB. All rights reserved.

2 Installation and commissioning 39

Product manual - IRB 460 5

3.2.3 Expected component life .......................................................................... 97

6 Product manual - IRB 460

5.1.2 Calibration methods ................................................................................. 354

7 Reference information 383

8 Spare parts 397

9 Circuit diagrams 399

Product manual - IRB 460 7

Overview of this manual

Who should read this manual?

Product manual scope

Continues on next page

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Product manual - IRB 460 13

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

Technical reference manuals

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Product manual - IRB 460 15

How to read the product manual

References to required equipment

16 Product manual - IRB 460

1.1.1 Limitation of liability

Spare parts and equipment

Product manual - IRB 460 17

1.1.2 Requirements on personnel

Personal protective equipment

18 Product manual - IRB 460

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

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Symbol Designation Significance

20 Product manual - IRB 460

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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Chain sling with shortener

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Shut off with handle

26 Product manual - IRB 460

1.3 Robot stopping functions

Protective stop and emergency stop

Product manual - IRB 460 27

1.4 Installation and commissioning

National or regional regulations

Securing the robot to the foundation

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