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3HAC039842 PM IRB 460-En
3HAC039842 PM IRB 460-En
Product manual
IRB 460
Trace back information:
Workspace 23C version a15
Checked in 2023-10-03
Skribenta version 5.5.019
Product manual
IRB 460 - 110/2.4
IRC5, OmniCore
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 Safety during installation and commissioning ......................................................... 28
1.5 Safety during operation ...................................................................................... 31
1.6 Safety during maintenance and repair ................................................................... 32
1.6.1 Safety during maintenance and repair ......................................................... 32
1.6.2 Emergency release of the robot axes .......................................................... 35
1.6.3 Brake testing .......................................................................................... 36
1.7 Safety during troubleshooting .............................................................................. 37
1.8 Safety during decommissioning ........................................................................... 38
3 Maintenance 95
3.1 Introduction ...................................................................................................... 95
4 Repair 137
4.1 Introduction ...................................................................................................... 137
4.2 General procedures ........................................................................................... 138
4.2.1 Performing a leak-down test ...................................................................... 138
4.2.2 Mounting instructions for bearings ............................................................. 139
4.2.3 Mounting instructions for sealings .............................................................. 141
4.2.4 Cut the paint or surface on the robot before replacing parts ............................ 145
4.2.5 The brake release buttons may be jammed after service work ......................... 146
4.3 Complete robot ................................................................................................. 147
4.3.1 Replacing cable harness, lower end (axes 1-3) ............................................. 147
4.3.2 Replacing the cable harness, upper end (incl. axis 6) ..................................... 157
4.3.3 Replacing customer cable harness (optional) ............................................... 164
4.3.4 Replacing the SMB unit ............................................................................ 174
4.3.5 Replacing the brake release board ............................................................. 179
4.3.6 Replacing the base, including axis 1 gearbox ............................................... 183
4.4 Upper and lower arm ......................................................................................... 192
4.4.1 Replacing the turning disk ........................................................................ 192
4.4.2 Replacing the tilthouse unit ....................................................................... 198
4.4.3 Replacing the upper arm .......................................................................... 219
4.4.4 Replacing linkage - upper link arm .............................................................. 236
4.4.5 Replacing linkage - lower link arm .............................................................. 244
4.4.6 Replacing the linkage - link ....................................................................... 251
4.4.7 Replacing the POM sealing for the link system ............................................. 267
4.4.8 Replacing parallel rod .............................................................................. 268
4.4.9 Replacing the complete lower arm system ................................................... 279
4.4.10 Replacing the parallel arm ........................................................................ 289
4.5 Motors ............................................................................................................ 297
4.5.1 Replacing motor, axis 1 ............................................................................ 297
4.5.2 Replacing motors, axes 2 and 3 ................................................................. 305
4.5.3 Replacing motor, axis 6 ............................................................................ 316
4.6 Gearboxes ....................................................................................................... 324
4.6.1 Replacing the axis 1 gearbox ..................................................................... 324
4.6.2 Replacing the axis 2 gearbox ..................................................................... 333
4.6.3 Replacing the axis 3 gearbox ..................................................................... 341
4.6.4 Replacing gearbox axis 6 .......................................................................... 348
5 Calibration 355
5.1 Introduction to calibration ................................................................................... 355
5.1.1 Introduction and calibration terminology ...................................................... 355
5.1.2 Calibration methods ................................................................................. 356
5.1.3 When to calibrate ................................................................................... 357
5.2 Synchronization marks and axis movement directions ............................................. 358
5.2.1 Synchronization marks and synchronization position for axes ......................... 358
5.2.2 Calibration movement directions for all axes ................................................ 359
5.3 Updating revolution counters ............................................................................... 360
5.3.1 Updating revolution counters on IRC5 robots ............................................... 360
5.3.2 Updating revolution counters on OmniCore robots ........................................ 364
5.4 Calibrating with Axis Calibration method ............................................................... 366
5.4.1 Description of Axis Calibration .................................................................. 366
5.4.2 Calibration tools for Axis Calibration ........................................................... 369
5.4.3 Installation locations for the calibration tools ............................................... 371
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 373
5.4.5 Reference calibration ............................................................................... 377
5.5 Verifying the calibration ...................................................................................... 379
5.6 Checking the synchronization position .................................................................. 380
6 Decommissioning 383
6.1 Introduction to decommissioning ......................................................................... 383
6.2 Environmental information .................................................................................. 384
6.3 Scrapping of robot ............................................................................................. 386
Index 403
Usage
This manual should be used during:
• installation and commissioning, from lifting the product to its work site and
securing it to the foundation, to making it ready for operation
• maintenance work
• repair work
• decommissioning work
Note
Prerequisites
A maintenance/repair/installation craftsman working with an ABB robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.
References
General
OmniCore robots
IRC5 robots
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.
Revision Description
• Method of replacing the base updated and bits holder added in section
Replacing the base, including axis 1 gearbox on page 183.
• 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 198.
• Procedures for Removal and Refitting updated in section Replacing
the upper arm on page 219.
• Three legged bearing puller added in Required equipment sections
Replacing linkage - upper link arm on page 236 and Replacing linkage
- lower link arm on page 244.
• Replacing method updated in section Replacing motors, axes 2 and
3 on page 305.
• Text updated in section Replacing the axis 1 gearbox on page 324.
• 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 41.
• Added an illustration that shows the directions of the robot stress
forces, see Loads on foundation, robot on page 42.
• Added new section about how to install the signal lamp, see Installation
of signal lamp, upper arm (option), on IRC5 robots on page 80.
• Added information that the working range of axis 1 also can be restric-
ted by EPS, see Introduction on page 85.
• 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 390.
• Added steps in the instruction for replacing upper end of cabling, see
Replacing the cable harness, upper end (incl. axis 6) on page 157.
• 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 60.
• 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 60.
• 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 119.
• 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 251
and Replacing the upper arm on page 219.
• Three o-rings are added to the equipment list and procedure in section
Replacing the axis 1 gearbox on page 324.
• 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: Installation of cooling fan
for axis-1 motor (Option 87-1) on page 74.
• The position of the battery holder for RMU lithium battery (3-pole
battery contacts) has changed. The figures and text has been updated.
Revision Description
E This revision includes the following updates:
• Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 386.
F This revision includes the following updates:
• New illustrations added for lower arm and lower and upper arm joints.
• The maximum allowed deviation in levelness of the base plate and
foundation is changed, see Securing the base plate on page 60.
• 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 60.
• 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 109.
• New standard calibration method is introduced (Axis Calibration). See
Calibration on page 355.
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 88.
• 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 369.
• 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.
Revision Description
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 145.
• New article numbers for manipulator cables in section Robot cabling
and connection points on page 89.
• 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 219.
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 141.
• 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 289.
• New number and instruction for press tool, tilt house, see Replacing
the tilthouse unit on page 198.
• New number and instruction for press tool, linkage - link, see Replacing
the linkage - link on page 251.
• Text regarding fastener quality is updated, see Fastener quality on
page 72.
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 164.
V Published in release 22B. The following updates are made in this revision:
• Controller OmniCore V250XT supported.
• Updated information about Gleitmo treated screws, see Screw joints
on page 390.
• Updated the drawing of fitting extra equipment on upper arm.
• Added the mounting/demounting tool (3HAC040021-001) to required
equipment list for replacement of upper arm, complete lower arm
system and axis-3 gearbox.
• Added procedure of applying rust preventive when replacing axis-2
and axis-3 gearboxes.
W Published in release 23A. The following updates are done in this revision:
• Added a step for overall inspection of cabling after cable harness has
been replaced.
• Updated the part number for Taper roller bearing in section Replacing
the tilthouse unit and the table for Required equipment.
X Published in release 23C. The following updates are done in this revision:
• Updated the tightening torque from 400 Nm to 800 Nm for securing
the upper arm shaft.
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
Product manuals
Manipulators, controllers, DressPack, and most other hardware is delivered with
a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Troubleshooting.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
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.
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.
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.
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 Safety information
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed as
intended.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
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.
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.
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.
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
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
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
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
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
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824
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
xx0900000827
Do not step
Warns that stepping on these parts can cause damage to the
parts.
xx1400002648
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 384 for specification of allergenic materials
in the product, if any.
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.
Note
Automatic operation
Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Hazards due to stored mechanical energy in the manipulator for the purpose of
counterbalancing axes must be considered before maintenance or repair.
Never use the robot as a ladder, which means, do not climb on the controller,
manipulator, including motors, or other parts. There are hazards of slipping and
falling. The robot might be damaged.
Make sure that there are no tools, loose screws, turnings, or other unexpected
parts remaining after maintenance or repair work.
When the work is completed, verify that the safety functions are working as
intended.
Hot surfaces
Surfaces can be hot after running the robot, and touching these may result in burns.
Allow the surfaces to cool down before maintenance or repair.
Allergic reaction
Allergic reaction
Note
Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox
Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Al-
ways use the type of oil specified
for the product.
Do not mix types of oil
Oil residues might be present in Make sure that protective gear
a drained gearbox and spilled like goggles/protective visor,
when separating a motor and gloves and arm protection are
gearbox during repair. always worn during this activity.
Put oil absorbent cloth or paper
Oil residues
at appropriate locations to catch
any oil residues.
Warm oil drains quicker than Run the robot before changing
cold oil. the gearbox oil, if possible.
Contaminated oil in
gearboxes
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
Related information
See also the safety information related to installation and operation.
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 57.
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.
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
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
CAUTION
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
Related information
See also the safety information related to installation, operation, maintenance, and
repair.
General
See section Decommissioning on page 383.
If the robot is decommissioned for storage, take extra precaution to reset safety
devices to delivery status.
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
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.
The technical data is detailed in section Technical data on page 41.
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.
For more information see:
• Product manual - OmniCore V250XT
• Product manual - OmniCore V250XT Type A
• Product manual - IRC5
• Product manual - IRC5 Compact
• Product manual - IRC5 Panel Mounted Controller
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.
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
Weight, robot
The table shows the weight of the robot.
Robot model Weight
IRB 460 925 kg
Note
The weight does not include tools and other equipment fitted on the robot.
Mounting positions
The table shows valid mounting options for the manipulator.
Mounting option Installation angle Note
Floor mounted 0°
Note
The actual mounting angle must always be configured in the system parameters,
otherwise the performance and lifetime is affected.
Txy
Fz
Fxy
Tz
xx1100000521
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
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.
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.
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).
xx1000001043
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
Risk of tipping
If the robot is not fastened to the foundation while moving the arm, the robot is not
stable in the whole working area. Moving the arm will displace the center of gravity,
which may cause the robot to tip over.
The transportation position is the most stable position.
Do not change the robot position before securing it to the foundation!
Transportation position
This figure shows the robot in its transportation position.
40°
25°
1707
692,5
94
627 380
773 907
xx1000001158
Note
WARNING
The robot will be mechanically unstable if not properly secured to the foundation.
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.
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.
Note
25°
94
627 380
773 907
xx1000001158
Action Note
3
DANGER
xx0600002910
Note
xx0600002930
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
Action Note
1 Make sure that the robot is in shipping
position! Note
2
DANGER
Action Note
4 Insert fork lift forks into the pockets. IRB 6620
CAUTION
xx0600002911
IRB 6640
Ax3
10°
A x2 5
45° Ax0°
8
xx0600003401
IRB 460
xx1000001159
Action Note
5 Remove the attachment bolts securing
the robot to the foundation.
6
CAUTION
WARNING
DANGER
General
The robot can be lifted with roundslings according to this section.
Sling specification
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 56.
3 Attach roundslings to robot according to fig-
ure Attachment points on page 56.
4
Note
5
CAUTION
6
WARNING
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
Note
xx1000001157
Note
Action Note
2
DANGER
xx0600002937
Required equipment
Hole configuration
xx0200000096
Action Note
1
CAUTION
CAUTION
Lift and move the base plate very slowly. If the base
plate starts to swing it is a risk for injuries or damage.
598,31
560,85
B 487,01
(Ø 8 455
00)
950
243,5
F 2x 450
12x M24 A E
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)
xx0400000715
B A
B
B
A
xx1500000312
xx0300000045
Required equipment
Base plate
This section details how to secure the base plate to the foundation.
Action Note
1 Make sure the foundation is levelled.
Action Note
2
CAUTION
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 62.
plate.
4 Lift the base plate to its mounting position. Detailed in section Lifting the base plate
on page 59.
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 62.
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.
General
This section details how to orient and secure the robot to the base plate in order
to run the robot safely.
xx0600002933
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
Note
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 65.
Shown in figure Illustration, robot fitted
to base plate on page 65.
Note
R400
4
x
15
°
4x3
7.5°
xx0600002932
xx0600002934
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.
Note! The weight of the extra equipment on the upper arm must be deducted from
the maximal handling capacity.
6xM10x1.5
94,3° 1.0
90
40
94,3°
70
15
50
315,5 30
50 788,5
20
25
30 6xM8 9 (B)
40
200
50
40
200
D
M10 (2x75) (A)
xx1000001041
xx1000001042
(B)
(A) X
xx1800001402
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
General
Any loads mounted on the robot must be defined correctly and carefully (with
regard to the position of center of gravity and mass moments of inertia) in order
to avoid jolting movements and overloading motors, gears and structure.
CAUTION
Incorrectly defined loads may result in operational stops or major damage to the
robot.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must be defined in the software.
• Operating manual - IRC5 with FlexPendant
• Operating manual - OmniCore
General
Note
The cooling fan is available only for robots with IRC5 controllers.
A cooling fan (option 87-1) can be installed on the axis-1 motor.
xx1300000168
xx1300000763
A Fan box
B Attachment screws (16 pcs)
C Groove in the connector
D Tightening screws (3 pcs)
Required equipment
Action Note
1
DANGER
xx1300000843
xx1300000844
Action Note
4 Insert and turn the connector so that the
groove points inwards, as shown in the figure.
xx1300000764
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.
xx1300000766
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
Note
xx1300000768
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.
xx1000001287
A Signal lamp
B Attachment screw M6x8 (2 pcs)
C Motor cover
Required equipment
B
x-x
x
x
F
xx1000001064
DANGER
4 Arrange the signal cable in a loop at the signal See figure Signal lamp kit on
cable bracket with two cable straps. page 81.
2 Remove the motor cover by unscrewing the four See figure Location of signal lamp,
attachment screws. upper arm on page 80.
3 Disconnect the motor connectors.
Action Note
4 Remove the cable gland cover at the cable exit See figure Signal lamp kit on
by removing the attachment screw. page 81.
Replace the screw with a longer one, when refit-
ting in following steps (enclosed in the signal
lamp kit).
xx0600002694
Description
A signal lamp with a yellow fixed light can be mounted in the cell or any other
visible location, and driven by I/O signal or MON_LAMP signal from the controller.
Function
The lamp is active in MOTORS ON mode.
Action
1
DANGER
Make sure that all supplies for electrical power, hydraulic pressure, and air pressure
are turned off.
Note
The local I/O connectors provides 16 digital output signals for use.
3 Configure the lamp by adding a System Output type signal with status set to Motors
On State.
4 The lamp is now ready for use and is lit in MOTORS ON mode.
Action
1
DANGER
Make sure that all supplies for electrical power, hydraulic pressure, and air pressure
are turned off.
2 The lamp is now ready for use and is lit in MOTORS ON mode.
Further information
Further information about the MOTORS ON/MOTORS OFF mode may be found in
the product manual for the controller.
Further information about how to set up I/O system may be found in Technical
reference manual - System parameters.
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.
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.
xx0600002938
Required equipment
2 Fit the additional mechanical stop to the Tightening torque: 120 Nm.
frame according to the figure Mechanical
stops, axis 1 on page 86.
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
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
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.
Introduction
Connect the robot and controller to each other after securing them to the foundation.
The lists below specify which cables to use for each respective application.
CAUTION
Connect the male and female connectors perfectly aligned horizontally to avoid
any kind of tilt or skew.
CAUTION
Verify that the serial number is according to the number(s) in the Declaration of
Incorporation (DoI).
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 (IRC5 con- R1.MP
drive units in the control cabinet trollers)
to the robot motors. X1 (OmniCore
controllers)
Robot cable, signals Transfers resolver data from XS2 (IRC5 con- R1.SMB
and power supply to the serial trollers)
measurement board. X2 (OmniCore
controllers)
A
B
xx1600002016
A Diameter
B Diameter x10
xx1600001956
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.
xx2100001979
xx2100001980
Safe handling
Use the following procedure after installation, maintenance, or repair, before
initiating motion.
DANGER
Initiating motion without fulfilling the following aspects, may increase the risk for
injury or cause damage to the robot.
Action
1 Remove all tools and foreign objects from the robot and its working area.
2 Verify that the robot is properly secured to its position by all screws, before it is powered
up.
3 Verify that any safety equipment installed to secure the position or restrict the robot
motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Verify that all safety equipment is installed, as designed for the application.
6 Verify that no personnel are inside the safeguarded space.
7 If maintenance or repair has been done, verify the function of the part that was main-
tained.
8 Verify the application in the operating mode manual reduced speed.
Collision risks
CAUTION
When programming the movements of the robot, always identify potential collision
risks before initiating motion.
3 Maintenance
3.1 Introduction
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.
For more information see:
• Product manual - OmniCore V250XT
• Product manual - IRC5
• Product manual - IRC5 Compact
• Product manual - IRC5 Panel Mounted Controller
• Robot cabling and connection points on page 89.
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.
The SIS used in OmniCore is further described in the Operating
manual - OmniCore.
Robots with the functionality Service Information System activated can show active
counters in the device browser in RobotStudio, or on the FlexPendant.
Overhaul
Depending on application and operational environment a complete overhaul may
be necessary in average around 40000 hours.
ABB Connected Services and its Assessment tools can help you to identify the
real stress level of your robot, and define the optimal ABB support to maintain your
robot working.
Contact your local ABB Customer Service to get more information.
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 99
Instructions for how to perform the different maintenance activities are found in
sections:
• Inspection activities on page 100
• Replacement/changing activities on page 119
• Cleaning activities on page 134
General
The expected life of a specific component of the robot can vary greatly depending
on how hard it is run.
Location of gearbox
The axis-1 gearbox is located between the frame and base. See oil plugs in the
following figure.
xx1000001294
Required equipment
2
DANGER
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 100.
5 Measure the oil level. A
Required oil level: max. 5 mm below the oil plug
hole.
C
xx1400002785
xx1000001295
A Gearbox, axis 2
B Oil plug, filling
xx1000001297
A Gearbox, axis 3
B Oil plug, filling
Required equipment
Action Note
2
DANGER
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
2
DANGER
xx1000001373
Required equipment
Visual inspection, no tools are needed.
6 Check the metal clamps on the lower arm. Shown in figure Location of cable har-
ness, axes 1-6 on page 107
7 Check the metal clamps holding the cable
harness inside the upper arm, as shown in
figure to the right.
xx0500002498
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
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
Inspecting, labels
Action Note
1
DANGER
WARNING
xx1000001302
Required equipment
Visual inspection, no tools are required.
Action Note
2 Inspect the axis-1 mechanical stop pin.
If the mechanical stop pin is bent or damaged, it
must be replaced.
Note
xx0600002938
Required equipment
Location of dampers
This figure shows the location of dampers.
xx1000001345
Required equipment
Inspecting, dampers
Use this procedure to inspect the dampers.
Action Note
1
DANGER
2 Check all dampers for damage, cracks or existing Shown in figure Location of
impressions larger than 1 mm. dampers on page 115.
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 115.
F
A
x-x
xx1000001288
Action Note
2
DANGER
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 117.
• 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.
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.
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
xx1000001294
xx1000001346
Required equipment
2
WARNING
3 Remove oil plug, filling, in order to drain oil quicker! Shown in Location of oil plugs on
page 120.
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 120.
Vessel capacity is specified in
Required equipment on page 121.
Note
Draining is time-consuming.
Elapsed time depends on the
temperature of the oil.
2
WARNING
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 100. and amount of oil in gearboxes
on page 119.
5 Refit the oil plug, filling. Tightening torque: 25 Nm.
xx1000001348
xx1000001351
Required equipment
2
WARNING
2
WARNING
Action Note
3 Remove the oil plug, filling. (Ventilation hole Shown in Location of oil plugs on
plug should also be removed.) page 124.
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 125.
amount that was previously drained.
5 Refit oil plug,filling and ventilation hole plug. Shown in Location of oil plugs on
page 124.
Tightening torque: 25 Nm.
xx1000001353
Required equipment
Draining, oil
Use this procedure to drain oil from gearbox axis 6.
When using oil change equipment, follow the instructions enclosed with kit.
Action Note
1 Put tilt house in a suitable position.
Action Note
2
DANGER
3 Drain oil from gearbox into a vessel by removing Shown in figure Location of oil plugs
oil plug, draining. on page 128.
Also remove oil plug, filling. Vessel capacity is specified in Re-
quired equipment on page 128.
4 Refit oil plugs, draining and filling. Tightening torque: 24 Nm.
Filling, oil
Use this procedure to fill gearbox axis 6 with oil.
When using oil change equipment, follow the instructions enclosed with kit.
Action Note
1
DANGER
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 the operating manual for
the robot controller for instructions.
WARNING
xx1000001360
A
B
xx1300001116
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!
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.
Action Note
2
DANGER
3
ELECTROSTATIC DISCHARGE (ESD)
4 Remove the SMB battery cover by unscrewing the Shown in figure Location of SMB
attachment screws. battery on page 130.
CAUTION
5 Pull out the battery and disconnect the battery Shown in figure Location of SMB
cable. battery on page 130.
6 Remove the SMB battery. Shown in figure Location of SMB
Battery includes protection circuits. Only replace battery on page 130.
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
2
ELECTROSTATIC DISCHARGE (ESD)
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 131.
Shown in figure Location of SMB
Note battery on page 130.
C
RMU batteries are installed together with a battery
holder to be properly secured inside the recess.
See figure.
A
B
xx1300001116
DANGER
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
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 100.
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.
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.
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.
4 Repair
4.1 Introduction
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
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.
For more information see:
• Product manual - OmniCore V250XT
• Product manual - IRC5
• Product manual - IRC5 Compact
• Product manual - IRC5 Panel Mounted Controller
Required equipment
Action Note
1 Finish the refitting procedure of the motor or gear in
question, but do not refill the gearbox with oil before
performing the leak-down test.
2 Remove the upper oil plug on the gear and replace
it with the leak-down tester.
Regulators, which are included in the leak-down test,
may be required.
3 Use caution, apply compressed air and raise the Correct value:
pressure with the knob until the correct value is 0.2-0.25 bar (20-25 kPa)
shown on the manometer.
CAUTION
General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment
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
General
This section describes how to mount different types of sealings.
Equipment
Rotating sealings
The following procedures describe how to fit rotating sealings.
CAUTION
Radial sealings
A radial sealing consists of a flexible rubber lip bonded to a rigid metal case. Only
one side of the sealing is static with a metal insert.
xx2300000433
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 141.
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
A B C
xx2000000071
A Main lip
B Grease
C Dust lip
Note
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
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.
Action Note
3 Check the o-ring grooves and mating surfaces.
They should be free of pores, contamination
and obvious scratches/damage.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Check that the o-ring is not squashed outside
the o-ring groove.
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
Removing
Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
xx2300000950
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
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.
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 157.
xx1100000153
xx1100000154
Required equipment
xx1100000155
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 148.
6 Unscrew the screws of the cable guide axis 2
inside the lower arm and loosen the cable
guide.
xx1100000157
Action Note
10 Open the SMB cover carefully. See the figure Location of cable har-
ness - lower end (axes 1-3) on
page 148.
11 Disconnect connector R1.G on the battery
cable between the battery and the SMB unit.
Note
xx1000001330
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 157.
CAUTION
xx1000001331
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 148.
4 Reconnect the earth cable.
xx1100000156
Action Note
5 Refit the rear cover plate to the robot base with
its attachment screws.
xx1100000155
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 157.
14 Make an overall inspection of the installed cable See Inspecting, cable harness on
harness. page 107.
15 Update the revolution counter! See section Updating revolution
counters on IRC5 robots on page 360.
16
DANGER
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 147.
xx1100000158
R2.MP6
R2.FB6
xx1100000159
Required equipment
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 147.
harness, lower end.
4 Remove the axis 6 motor cover by removing
its attachment screws, in order to reach the
connectors.
xx1000001106
Action Note
Remove the cable gland cover at the cable
exit by unscrewing its attachment screw on
the inside.
Note
xx0600002694
xx1000001336
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
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
xx1000001336
Note
Action Note
8 Refit the cable gland with its attachment
screw.
xx0600002694
Note
xx1000001106
10 Make an overall inspection of the installed See Inspecting, cable harness on page 107.
cable harness.
11 Update the revolution counter! Detailed in section Updating revolution
counters on IRC5 robots on page 360.
12
DANGER
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
xx2100002528
Required equipment
xx2100002529
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
xx2100002530
xx2100002531
Action Note
5 Disconnect the connectors on the tilthouse unit.
For cable harness with Parallel + Devi-
ceNet/Profibus + air hoses
• R2.CBUS (A)
• R2.CPS (B)
• R2.CAIR (C)
xx2100002532
xx2100002533
xx2100002534
xx2100002535
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
xx2100002537
xx2100002538
xx2100002539
CAUTION
xx2100002538
xx2100002540
xx2100002537
Action Note
6 Fasten the metal clamps that hold the cable
harness in the upper arm with the nuts (2 pcs
+ 2 pcs).
xx2100002536
xx2100002535
xx2100002539
Action Note
9 Reconnect the connectors on the base.
For cable harness with Parallel + Devi-
ceNet/Profibus + air hoses
• R1.CP/CS (A)
• R1.PROC1 (B)
xx2100002530
xx2100002530
xx2100002531
Action Note
10 Reconnect the connectors on the tilthouse unit.
For cable harness with Parallel + Devi-
ceNet/Profibus + air hoses
• R2.CBUS (A)
• R2.CPS (B)
• R2.CAIR (C)
xx2100002532
xx2100002533
xx2100002534
11 Refit the rear cover plate to the robot base with Tightening torque: 6 Nm
its attachment screws.
xx2100002529
12
WARNING
Action Note
13
DANGER
xx1100000105
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!
3
ELECTROSTATIC DISCHARGE (ESD)
4 Remove the SMB cover by unscrewing its attachment Shown in the figure Location of
screws. SMB unit on page 174.
CAUTION
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
2
ELECTROSTATIC DISCHARGE (ESD)
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 174.
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 175.
Shown in the figure Location of SMB
unit on page 174.
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
Action Note
8 Secure the SMB cover with its attachment Shown in the figure Location of SMB
screws. unit on page 174.
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 360.
10
DANGER
xx1100000105
Required equipment
2
ELECTROSTATIC DISCHARGE
(ESD)
3 Remove the push button guard from the SMB Shown in the figure Location of brake
cover. release board on page 179.
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 179.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
CAUTION
Action Note
7 Disconnect the connectors X8, X9 and X10
from the brake release board.
X8
X10
X9
xx1700000978
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 179.
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 180.
WARNING
Action Note
6 Refit the SMB cover with its attachment Shown in the figure Location of brake
screws. release board on page 179.
7
WARNING
8 Refit the push button guard to the SMB cover. Shown in the figure Location of brake
release board on page 179.
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 360.
11
DANGER
Introduction
The term complete arm system used in this procedure is defined as the complete
robot excluding:
• base
• gearbox axis 1
xx1100000246
Required equipment
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 367.
no new reference values can be created,
then reference calibration is not possible.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
25°
m
xx1000001155
3
DANGER
Action Note
5 Remove the mechanical stop pin from the
frame.
xx1000001302
Note
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 184.
and prevent damage on the gearbox.
Action Note
14 Lift the complete arm system carefully and
secure it in a safe area. Note
Note
CAUTION
15 If needed, continue to remove the axis 1 See Replacing the axis 1 gearbox on
gearbox from the base. page 324.
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 184.
5 Fit a lifting eye and a shackle to the adapter. Art. no. is specified in Required equip-
ment on page 184.
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.
2 Refit the axis 1 gearbox, if it has been re- See Replacing the axis 1 gearbox on
moved. page 324.
3
CAUTION
Action Note
7 Fit two guide pins in the holes in the axis 1
gearbox, shown in the figure.
Tip
xx1100000257
Note
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 390.
Note
xx0600003070
Parts:
A Serrated lock washer (24 pcs)
B Axis 1 gearbox
C Attachment screws M12x110 qual-
ity 12.9 gleitmo (24 pcs)
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 147.
16 Refit the axis 1 motor. See Replacing motor, axis 1 on page 297.
17 Refit the mechanical stop pin to the frame.
xx1000001302
xx1100000132
Required equipment
xx1100000139
3
DANGER
Action Note
5 Drain the axis 6 gearbox. See section
• Changing oil, gearbox axis
6 on page 128
6 Remove the attachment screws that secure the
turning disk.
xx1100000075
xx1100000076
8 Foundry Plus:
Remove old flange sealant residues and other con-
tamination from the contact surfaces.
xx1100000140
xx0200000218
Action Note
2 Put some grease on the o-rings (6 pcs) and fit
them in turning disk as shown in the figure.
xx1100000080
xx1100000139
4 Foundry Plus:
Apply Loctite 574 flange sealant on the contact
surface.
xx1400000995
Action Note
5 Secure the turning disk with its attachment
screws.
xx1100000078
Introduction
This section describes how to replace the tilthouse unit. The section consists of
these parts:
• Location of tilthouse unit on page 199
• Location of axes 2 and 3 sides of the robot on page 200
• X-ray view of the assembly of the tilthouse unit on page 202
• Press tool for removal of shaft on page 203
• Removing the tilthouse unit on page 206
• Premounting outer race of bearing and radial sealing, axis 2 side on page 212
• Premounting outer race of bearing and radial sealing, axis 3 side on page 213
• Refitting shafts on page 214
• Refitting lock nuts and the remaining parts on page 216
xx1100000213
xx1100000214
xx1100000215
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
A B C D E F G H A
xx1100000252
(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
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 367.
no new reference values can be created,
then reference calibration is not possible.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
xx1100000225
Action Note
3 This is done in order to prevent the tilthouse
from falling down when the upper link is re-
moved.
DANGER
xx1100000226
4
DANGER
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 316
be damaged.
Action Note
7 Disassemble the upper link arm from the tilt- See Replacing linkage - upper link arm
house unit. on page 236
Note
xx1100000228
xx1100000230
Action Note
9 Be careful not to damage the ball plug!
Note
xx1100000231
CAUTION
xx1100000232
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 202.
figure in: The longer threaded bar: M16 length
• Press tool for removal of shaft on 450 mm
page 203
Note
Action Note
15 Press out the shaft with the press tool.
xx1100000235
xx1100000236
Action Note
20 Remove the tilthouse and lift it to a safe place.
Check that bearings are kept clean. Replace if
damaged.
xx1100000237
xx1100000243
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 202.
If needed apply the press tool pre-mounting
bearing and fit the outer race of the bearing. Note
xx0900000813
DANGER
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.
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 202.
If needed apply the press tool pre-mounting
bearing and fit the outer race of the bearing.
xx0900000813
DANGER
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 202.
Refitting shafts
Before starting this procedure, prepare the tilthouse as described in:
• Premounting outer race of bearing and radial sealing, axis 2 side on page 212
• Premounting outer race of bearing and radial sealing, axis 3 side on page 213
Use this procedure to refit the shafts of the tilthouse unit.
Action Note
1
CAUTION
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
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 202.
5 See Location of axes 2 and 3 sides of
Note the robot on page 200.
Action Note
6 Push the shaft into its hole, from the inside. The figure shows IRB 760 but the
principle is the same.
xx1000001438
Action Note
2 Place the inner race of the bearing on the shaft
on the axis 2 side and push it in position.
Note
Note
Note Note
Flat side of the lock nut facing inwards! Rotate the tilthouse while securing the
lock nut on the axis 3 side.
Action Note
15 Recalibrate the robot. Axis Calibration is described in Calib-
rating with Axis Calibration method on
page 366.
General calibration information is in-
cluded in section Calibration on
page 355.
16
DANGER
xx1100000262
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
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
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 B C D E F G
xx1100000270
Required equipment
Action Note
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Action Note
11 Remove the parallel rod. For more information, see Replacing
parallel rod on page 268.
Note
xx1100000266
Note
xx1100000267
Parts:
• A: Radial seal with dust lip
• B: Sleeve
• C: O-ring
Action Note
3 Remove the set screws securing the axis 2
and 3 shafts. One on each shaft.
xx1100000263
xx1100000264
xx1100000265
• A: Protective cover
• B: Adapter
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
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
Action Note
3 Check that the bushings in the upper arm are
without damages and still in the correct posi-
tion.
Note
xx1100000271
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 223
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
xx1900001714
xx1900001205
Action Note
2 Carefully fit the shaft into the threads of the
upper arm, by hand only.
Note
xx1100000264
xx1100000265
• A: Protective cover
• B: Adapter
Secure the shaft.
Tightening torque: 800 Nm.
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
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
Note
Note
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
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!
1 Tighten the lock nut with a tightening
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.
4 Tighten the lock nut with a tightening
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.
xx1100000263
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 244
• Replacing the linkage - link on page 251
xx1100000167
Required equipment
CAUTION
xx1000001132
Action Note
3
CAUTION
xx1100000173
4
DANGER
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
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
xx1100000172
Parts:
A Radial sealing ring
B Bearing
C Radial sealing ring
9 Remove residual grease.
Note
xx1100000172
Parts:
A Radial sealing ring
B Bearing
C Radial sealing ring
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
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
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 236
• Replacing the linkage - link on page 251
xx1100000167
Required equipment
Action Note
2
CAUTION
xx1100000173
xx1100000170
Parts:
A Lock screw
B Locking washer
Action Note
4 Remove the locking washer.
xx1100000171
Note
xx1100000174
Action Note
6 Remove the radial sealing rings.
xx1100000172
Parts:
A Radial sealing ring
B Bearing
C Radial sealing ring
7 Remove residual grease and sealing com-
pound.
2 Lubricate the bearings properly with bearing For art. no. see Required equipment on
grease. page 245.
Action Note
3 Fit the radial sealing rings in the lower link
arm as shown in the figure.
xx1100000172
Parts:
A Radial sealing ring
B Bearing
C Radial sealing ring
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
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
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 236
• Replacing linkage - lower link arm on page 244
Location of link
The link is located as shown in the figure.
xx1100000167
xx1100000212
A VK cover
B Lock nut
C Bearing
D Bearing
E POM Sealing
xx1300000007
A VK cover
B Lock nut
C Bearing
D Bearing
E Support ring, including o-ring
F Radial sealing
Required equipment
Action Note
2
DANGER
CAUTION
xx1100000173
4 Remove upper and lower link arms. How to remove upper link arm see:
• Replacing linkage - upper link arm
on page 236
How to remove lower link arm see:
• Replacing linkage - lower link arm
on page 244
Action Note
5 Remove screw and washer in the hole for
filling grease.
xx1100000196
CAUTION
xx1100000195
Action Note
7 Remove the lock nut (KM8).
xx1100000197
Note
xx1100000198
Action Note
12 Remove the POM sealing or the support ring
(depending on version of sealing structure).
xx1100000199
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 253
xx0900000813
DANGER
xx1300000006
xx1300000005
xx1300000008
Action Note
4 Valid for design with support ring.
Fit the support ring with the included o-ring
on the shaft. Use a plastic mallet, if neces-
sary.
Note
xx1300000004
xx1100000200
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 253.
press tool link.
xx1100000201
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 253.
Action Note
11 Apply locking liquid on the lock nut. Loctite 243
xx1100000197
xx1100000204
Action Note
14 Refit the VK cover.
xx1100000205
xx1900001001
A Vent hole
Action Note
16 Fill the link with grease. Art.no. is specified in Required equipment
on page 253
xx1900000923
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 236
19 Refit the lower link arm. See section Replacing linkage - lower link
arm on page 244
20 Recalibrate the robot! Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 366.
General calibration information is included
in section Calibration on page 355.
Action Note
21
DANGER
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 251.
xx1100000212
A VK cover
B Lock nut
C Bearing
D Bearing
E POM Sealing
xx1100000164
Required equipment
xx1100000166
A Thread bush
B Support bush
C Hydraulic cylinder
D Thread washer
2
CAUTION
Action Note
3 Remove the lock screw and washer, securing
the shaft of the parallel rod in position.
xx1100000141
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 268
Action Note
6 Remove the upper shaft.
xx1100000144
xx1100000146
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.
xx1100000165
A Thread bush
B Support bush
C Hydraulic cylinder
Continues on next page
Product manual - IRB 460 273
3HAC039842-001 Revision: X
© Copyright 2012-2023 ABB. All rights reserved.
4 Repair
4.4.8 Replacing parallel rod
Continued
D Tread 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
Action Note
5 Place the other POM sealing on the axis 3
side.
xx1100000151
xx1100000161
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
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
Action Note
13
DANGER
xx1100000175
A Lower arm
B Parallel arm
Required equipment
Action Note
2
DANGER
xx1000001179
Action Note
9
CAUTION
xx1100000179
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
Action Note
13 Remove all attachment screws (M12) secur-
ing the lower arm system, on both sides.
xx0200000165
A: Rotation tool
Note
xx1100000181
Action Note
16
DANGER
xx1100000182
xx1100000178
Action Note
18 Remove the complete lower arm system.
xx1100000183
Action Note
3 Fit a roundsling, to the lower arm system and
lift it up.
DANGER
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 279
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
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
xx1000001179
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 305.
14 Refit the complete upper arm. See section Replacing the upper arm on
page 219.
15 Refit the cable harness in the upper arm and See Replacing the cable harness, upper
lower arms. end (incl. axis 6) on page 157 and Repla-
cing cable harness, lower end (axes 1-3)
on page 147.
16 Refit the parallel rod. See section Replacing parallel rod on
page 268
17 Refit the linkage starting with the link. See sections:
• Replacing the linkage - link on
page 251
• Replacing linkage - lower link arm
on page 244
• Replacing linkage - upper link arm
on page 236
18 Remove the lock screw.
19 Recalibrate the robot. Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 366.
General calibration information is included
in section Calibration on page 355.
20
DANGER
xx1100000176
A Lower arm
B Parallel arm
Required equipment
Action Note
3
DANGER
4
DANGER
xx1100000182
5
CAUTION
Action Note
6 Secure the lower arm system as shown in
the figure.
xx1100000184
Tip
xx1100000186
8
CAUTION
Action Note
10 Remove the parallel arm from the lower arm
by lifting it straight up.
Tip
xx1100000187
xx1100000189
xx1100000218
xx0900000813
DANGER
xx1100000193
4 Apply some grease in the hole for the bear- Art. no. is specified in Required equip-
ing. ment on page 289
xx1100000192
Action Note
5
CAUTION
Tip
xx1100000194
xx1400000070
9 Refit the complete lower arm system. See section Replacing the complete lower
arm system on page 279.
10 Recalibrate the robot. Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 366.
General calibration information is included
in section Calibration on page 355.
Action Note
11
DANGER
4.5 Motors
xx1000001171
Required equipment
xx1000001165
Action Note
4 Remove the cable gland cover at the cable exit
of the motor.
Note
xx1000001166
xx1000001167
Action Note
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
xx1100000087
9
CAUTION
CAUTION
xx1000001168
xx1000001096
Parts:
A Circumference of motor
B O-ring
Note
2
CAUTION
Action Note
4 Gently lower the motor into the gear, making
sure the pinion is properly mated to the gearbox
of axis 1.
Note
Note
xx1000001169
xx1000001167
Attachment screws:
• M10x40 quality 12.9 Gleitmo
Tightening torque:
• 50 Nm
6 Disconnect the brake release voltage.
7 Reconnect all connectors beneath the motor
cover.
Action Note
8 Refit the cable gland cover at the cable exit with
its attachment screws.
Note
xx1000001166
Note
xx1000001165
xx1000001174
Required equipment
Action Note
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
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!
Action Note
5
DANGER
xx1000001182
Note
xx1000001183
Action Note
10 In order to release the brake, connect the 24 Connect to connector R2.MP2
VDC power supply. • + : pin 2
• -: pin 5
11 Unscrew attachment screws and washers of
the motor. Use the bits extension.
xx1000001181
12 Fit two guide pins in two of the motors attach- Art. no. is specified in Required
ment holes. equipment on page 305.
The figure shows IRB 760 but the
principle is the same.
xx1000001131
Action Note
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 305.
15
CAUTION
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
Action Note
18 Disconnect the brake release voltage!
19 Check the pinion. If there is any damage, the
motor pinion must be replaced.
xx1000001186
Parts:
• B: O-ring
• C: Circumference
2 In order to release the brake, connect the 24 Connect to connector R2.MP1
VDC power supply. • + : pin 2
• -: pin 5
3 Fit the lifting tool, motor axes 2-3 to the motor. Art. no. is specified in Required
equipment on page 305.
Action Note
4 Fit the two guide pins in the two lower motor Art. no. is specified in Required
attachment holes. equipment on page 305.
The figure shows IRB 760 but the
principle is the same.
xx1000001131
5
CAUTION
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
xx1000001185
Action Note
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
Part:
Rotation tool
9 Remove the guide pins.
10 Secure the motor with its four attachment
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 390 before fitting.
xx1000001181
Attachment screws:
• M10 x 40 quality 12.9 Gleitmo
Tightening torque:
• 50 Nm
11 Disconnect the brake release voltage.
12 Reconnect all connectors beneath the motor Connect in accordance with markings
cover. on connectors.
Action Note
13 Refit the cable gland cover at the cable exit with
its two attachment screws.
Note
xx1000001183
Note
xx1000001182
Action Note
15 Remove the lock screw from the hole for lock
screw.
xx1000001179
xx1100000090
Required equipment
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
3
DANGER
xx1000001223
Note
xx0600002694
Action Information
A
6 Disconnect all connectors beneath the
cover.
B
Note
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
Action Information
10 Lift the motor carefully to get the pinion
away from the gear.
Note
xx1000001226
Note
xx1000001109
Parts:
• A: Pinion
• B: O-ring
• C: Circumference
Action Information
2 In order to release the brake, connect the 24 Connect to connector R2.MP6
VDC power supply. • + : pin 2
• -: 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 316.
4 Lift the motor carefully in place.
Make sure the motor pinion is properly mated
to the gearbox, axis 6.
Note
xx1000001228
xx1000001225
Washers:
• 8.4x16x1.6 quality Steel-A2F
Attachment screws:
• M10 x 40 quality 8.8-A2F
Tightening torque:
• 50 Nm
Continues on next page
Product manual - IRB 460 321
3HAC039842-001 Revision: X
© Copyright 2012-2023 ABB. All rights reserved.
4 Repair
4.5.3 Replacing motor, axis 6
Continued
Action Information
8 Disconnect the brake release voltage.
9 Perform a leak-down test of the axis 6 gearbox. See section Performing a leak-down
test on page 138.
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
xx0600002694
Action Information
14 Refit the cover, motor axis 6 with its attachment
screws and washers.
Note
xx1000001223
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
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 367.
no new reference values can be created,
then reference calibration is not possible.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
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
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 324.
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
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
xx1000001387
14
CAUTION
Action Note
16 Turn the gearbox, and remove the protec-
tion pipe by unscrewing two attachment
screws.
Note
xx1400000786
xx1000000364
Action Note
3 Fit two lifting eyes on each side of the gear- Specified in Required equipment on
box. page 324.
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 324.
5
CAUTION
xx1300000015
7 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs!
lower it carefully to its mounting position.
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 390 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
Action Note
13 Refit the complete arm system. See Replacing the base, including axis
1 gearbox on page 183.
CAUTION
xx1100000123
Required equipment
Note
Do not replace both gearboxes at the same time, unless the complete arm system
is already removed!
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 Drain the gearbox from oil. Also see
Note
Time-consuming activity!
xx1000001179
Action Note
7
DANGER
xx1100000219
xx1100000220
Note
4
CAUTION
5 Fit the lifting tool to the gearbox. Art. no. is specified in Required equip-
ment on page 333.
Action Note
6 Unscrew the M12 attachment screws secur-
ing the gearbox to the lower arm system.
xx1100000221
xx1100000223
Action Note
5 Apply rust preventive on the frame inner
surfaces that contact with the gearbox.
xx2200000709
xx1100000224
2 Fit the lifting tool to the gearbox. Art. no. is specified in Required equip-
ment on page 333.
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.
Action Note
6 Secure the gearbox and the motor flange to
the frame with the attachment screws and
washers.
xx1100000219
xx1100000221
Action Note
3 Apply rust preventive on the exposure sur-
faces of the gearbox.
xx2200000710
xx1000001179
xx1100000123
Required equipment
Note
Do not replace both gearboxes at the same time, unless the complete arm system
is already removed!
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 Drain the gearbox from oil. Draining, axes 2 and 3 on page 126
Note
Time-consuming activity!
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 305.
6 Unscrew the attachment screws of the motor
flange and lift away the washers and the
motor flange.
xx1100000219
xx1100000220
Note
8
CAUTION
xx1100000223
xx2200000707
xx1100000224
Action Note
7 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.
8
CAUTION
9 Fit the lifting tool to the gearbox. Art. no. is specified in Required equip-
ment on page 333.
xx1100000219
Action Note
7 Apply rust preventive on the exposure sur-
faces of the gearbox.
xx2200000708
8 Jog axes 2 and 3 to a position where the re- Tightening torque: 120 Nm
maining attachment screws can be fitted and
secured.
9 Jog axis 3 (the parallel arm) very carefully to
the position where the parallel rod can be
refitted to the parallel arm.
10 Refit the parallel rod. See Replacing parallel rod on page 268.
11 Perform a leakdown test. See Performing a leak-down test on
page 138.
12 Refill the gearbox with oil. Draining, axes 2 and 3 on page 126
13 Recalibrate the robot. Axis Calibration is described in Calibrat-
ing with Axis Calibration method on
page 366.
General calibration information is included
in section Calibration on page 355.
14
DANGER
xx1100000124
Required equipment
Action Note
2 Jog the robot to a position where the tilt-
house unit is placed in an appropriate ser-
vice position.
3
DANGER
xx1100000239
xx1100000229
Action Note
8 If required apply two M8 screws in the holes
shown in the figure, and press out the
gearbox.
xx0200000220
xx1000001412
xx1100000240
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 348.
replace!
Lubricate the o-ring with grease.
xx1100000241
xx1100000240
Action Note
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
xx1100000242
xx1100000229
Action Note
10 Refit the calibration plate.
xx1100000239
5 Calibration
5.1 Introduction to calibration
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 366.
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.
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
References
Article numbers for the calibration tools are listed in the section Special tools on
page 395.
When to calibrate
The system must be calibrated if any of the following situations occur.
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
xx1000001433
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.
xx0500001927
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.
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).
xx1500000942
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943
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
en0400000771
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
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.
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).
Action
3 In the Selection column select the axes for which revolution counters need to be up-
dated.
4 Tap Update.
A dialog box is displayed warning that the updating operation cannot be undone.
5 Tap OK to update the revolution counter.
6
CAUTION
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.
Note
When calibrating the robot with the reference calibration routine, the robot must
be dressed with the same tools, process cabling and any other equipment as
when the reference values were created.
Note
When using reference calibration with some tools, typically large or flexible tools,
oscillations in the robot can cause issues leading to failure of the calibration.
If calibrating the robot with reference calibration there must be reference values
created before repair is made to the robot, if values are not already available.
Creating new values requires possibility to move the robot. The reference values
contain positions of all axes, torque of axes and technical data about the tool
installed. A benefit with reference calibration is that the current state of the robot
is stored and not the state when the robot left the ABB factory. The reference value
will be named according to tool name, date etc.
Follow the instructions given in the reference calibration routine on the FlexPendant
to create reference values.
When reference calibration is performed, the robot is restored to the status given
by the reference values.
Validation
In the mentioned routines, it is also possible to validate the calibration data.
These axes are marked with Unrestricted in the FlexPendant window. Also the
following table shows the dependencies between the axes.
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.
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
xx1500001914
A Tube insert
B Plastic protection
C Steel spring ring
xx1500000951
A Outer diameter
xx1700000437
xx1700000438
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.
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.
Required consumables
Consumable Article number Note
Clean cloth -
Spare parts
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.
Note
Note
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.
Action Note
5 Valid for RobotWare 7
Tap Calibration Methods on the right pane and
then tap Calibration. The software will automatic-
ally call for the procedure for the valid calibration
method.
6 Follow the instructions given on the FlexPendant. A brief overview of the sequence
that will be run on the FlexPendant
is given in Overview of the calibra-
tion procedure on the FlexPendant
on page 373.
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
Action Note
3 Reinstall the protective plug and sealing in the
bushing on each axis, directly after the axis has
been calibrated. Ensure that the sealing is not
damaged.
Replace the plug and the sealing with new spare
part, if missing or damaged.
xx1500000952
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
Introduction
Check the synchronization position of the robot before beginning any programming
of the robot system. This may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the FlexPendant.Using the Jog window on
the FlexPendant.
6 Decommissioning
6.1 Introduction to decommissioning
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
Note
Transportation
Prepare the robot or parts before transport, this to avoid hazards.
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
xx1900000803
Green symbol with "e" in it: The product does not contain any hazardous substances
exceeding concentration limits and is a green environmentally friendly product
which can be recycled.
Note
DANGER
7 Reference information
7.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.
General
The product is compliant with ISO 10218-1:2011, Robots for industrial environments
- Safety requirements - Part 1 Robots, and applicable parts in the normative
references, as referred to from ISO 10218-1:2011. In case of deviation from ISO
10218-1:2011, these are listed in the declaration of incorporation. The declaration
of incorporation is part of the delivery.
Robot standards
Standard Description
ISO 9283 Manipulating industrial robots – Performance criteria and re-
lated test methods
ISO 9787 Robots and robotic devices – Coordinate systems and motion
nomenclatures
ISO 9946 Manipulating industrial robots – Presentation of characteristics
Standard Description
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements, normative reference from ISO 10218-
1
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
standards – Emission standard for industrial environments
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design, normative reference
from ISO 10218-1
Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require-
ments
EN ISO 10218-1 Robots and robotic devices — Safety requirements for indus-
trial robots — Part 1: Robots
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
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.
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
Tightening torque for oil-lubricated screws with slotted or cross-recess head screws
The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Note
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
Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M24 680 960 1150
Tightening torque for lubricated screws (Molykote, Gleitmo or equivalent) with allen head screws
The following table specifies the recommended standard tightening torque for
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Note
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
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.
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 394, and of special tools, listed directly in the instructions
and also gathered in this section.
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
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
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
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
9 Circuit diagrams
9.1 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
Manipulators
symbols, 19 T
symbols on robot, 21 temperatures
test run, 94 operation, 43
safety devices, 29 storage, 43
safety equipment testing
mechanical stop, 86 brakes, 36
signal lamp, 117 tools
safety hazard Axis Calibration, 395
hydraulic system, 30 for service, 395
pneumatic system, 30 torques on foundation, 42
safety signals transportation, 383
in manual, 19 troubleshooting
safety standards, 388 oil spills, 134
scales on robot, 358 safety, 37
schedule for maintenance, 97 turning disk dimensions, 71
screw joints, 390 turning disk replacement, 192
securing
base plate, 60 U
securing, robot, 65 UL lamp, installation, 80
securing the robot to foundation, attachment screws, 65 upcycling, 384
shipping, 383 updating revolution counters, 360, 364
signal lamp upper arm
installing, 84 dimensions, 69
signal lamp, installation, 80 users
signals requirements, 18
safety, 19
SMB V
replacing, 174 validity and responsibility, 17
SMB battery velocity
extension of lifetime, 130, 174 adjusting, 88
replacing, 130, 174 verifying calibration, 379
special tools, 395
speed W
adjusting, 88 weight, 41
stability, 47 base plate, 59, 64
standards, 388 robot, 54–55, 186, 189, 211, 214, 225, 229, 282, 285,
ANSI, 388 291–292, 295, 301–302, 310, 312, 327–328, 330–
CAN, 388 331, 336, 338, 344, 346
start of robot in cold environments, 88 working range, 45
steel restricting axis 1, 86
disposal, 384 X
storage conditions, 43 xx
symbols replacing, 92
safety, 19
synchronization position, 360, 364 Z
sync marks, 358 zero position
system integrator requirements, 28 checking, 380
ABB AS
Robotics & Discrete Automation
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Inc.
Robotics & Discrete Automation
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC039842-001, Rev X, en